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PRODUCTION PROCESS OF CENTRIFUGAL CONCRETE PIPES FOR WATER DRAINING WORKS

INTERNAL CIRCULATION ONLY ISSUED TOGETHER WITH DECISION NO. DATE : 2012

QTSXOBT- VIWASEEN 12

PIPE PRODUCTION PROCESS

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DESCRIPTION OF
PRODUCTION PROCESS OF CENTRIFUGAL CONCRETE PIPES FOR WATER DRAINING WORKS

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I.

MATERIALS FOR PIPE PRODUCTION


1) Reinforcement

Reinforcement used for concrete pipes of drainage is hot rolled steel, type of C1(similar to A1), strength of R=kg/cm2( old TC of 2100 kg/cm2); Used Diameter: D6, D8, D10, Meeting the Vietnamese standards: TCVN 6285-1997; TCVN 6286-1997 Reinforcement is clean, free from rust, and is straighten before processing. 2) Cement Poorland cement, PCB30 or PCB40, 50 kg bang of cement or cement delivered in bulk by specialized vehicles to pump into silo. Meeting TCVN 2682-1999; or TCVN 2682-1997 3) Sand Sand for concrete is clean, screened carefully, free form impurities such as mud, grass, and unsound wood; sand particles are of equal size. Meeting TCVN 7570:2006- TCVN 7572:2006. 4) Ballast Ballast used in pipe production is of standard size (1x2 cm); clean, equal size, physico mechanical, tested, and suitable with requirements Meeting TCVN 7570:2006; TCVN 7572:2006 5) Water Water used for concrete is from water resource, running water, water well meeting the standard of domestic water: TCXDVN 302- 2004; 6) Admixture There are many kinds of admixture: enhancing advance; plasticity, corrosion resistance (sulfate resistance) In case of fast delivery, early removing mold, it is necessary to use admixture of advance enhancement. Mixture ratio is in accordance with instruction of manufacturers. There are admixtures such as Sika, MBT,

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7) Concrete mix design Mix proportion for materials for 1 m3 of concrete using PCB 30 cement Slump: 2 4 cm Rock: dmax = 20 mm [(4070)% having the size of 0.5 x 1 cm and (6030)% having the size of 1 x 2 cm Concrete grade 100 150 200 250 300 Materials used for 1m3 of concrete Sand (m3) Rock (m3) Water (litre) 0.516 0.905 185 0.493 0.891 185 0.469 0.878 185 444 0 0.444 0.865 0.865 185 170

XM (kg) 218 281 342 405 439

Admixture

plasticity

Mix proportion for materials for 1 m3 of concrete using PCB 40 cement Slump: 2 4 cm Rock: dmax = 20 mm [(4070)% having the size of 0.5 x 1 cm and (6030)% having the size of 1 x 2 cm Concrete grade 150 200 250 300 350 400 Materials used for 1m3 of concrete Sand (m3) Rock (m3) Water (litre) 0.51 0.903 185 0.493 0.891 185 0.475 0.881 185 0.449 0.800 210 0.432 0.860 187 0.444 0.865 174

XM (kg) 233 281 327 396 425 439

Admixture

plasticity

(According to the standards of Transportation Ministry) Unit weight: symbol (t/m3; kg/m3) determined in laboratory under dry condition. In case of weather change, humidity has obvious influence on unit weight of materials (sand, rock). Dry season:

of sand = 1,15 1,2 of sand = 1,25 1,28 Mix proportion for materials for 1 m3 of concrete using PCB 40 cement
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Slump: 2 4 cm Rock: dmax = 20 mm [(4070) % having the size of 0.5 x 1 cm and (6030) % having the size of 1 x 2 cm. Materials used for 1 m3 of concrete XM (kg) Sand (m3) Sand (kg) Rock (m3) 233 281 327 374 425 439 0.51 0.493 0.475 0.457 0.432 0.444 548 591 0.903 0.891 0.881 0.872 0.860 0.865 1116 1140 Rock (kg) Water (litre) 185 185 185 185 187 174 Admixture

Concrete grade 150 200 250 300 350 400

Rainy season: (outdoor sand, humidity > 80%) It is required to increase the volume of sand and rock and to decrease water at the same time. of sand = 1.28 1.35 of sand = 1.28 1.35 Mix proportion for materials for 1 m3 of concrete using PCB 40 cement Slump: 2 4 cm Rock: dmax = 20 mm [(4070) % with the size of 0.5 x 1 cm and (6030) % with the size of 1 x 2 cm. Materials used for 1m3 of concrete Concrete Rock Rock Water XM (kg) Sand (m3) Sand (kg) Admixture grade 3 (m ) (kg) (litre) 150 233 0.51 0.903 185 200 281 0.493 641 0.891 1203 165 250 327 0.475 0.881 185 300 374 0.457 594 0.872 1177 170 350 425 0.432 0.860 187 400 439 0.444 0.865 174
1. Concrete shall be mixed according to the required mix proportion,

materials shall meet the standards


2. Sampling specimen of 15x15x15 cm or field-cured cylinders of D100,

D150 in accordance with TCVN 3105-1993;


3. Testing specimen compressed for 7 days, 14 days, 28 days, etc.

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4. Mix proportion for concrete shall be tested prior to putting into

production
5. In case of change in material supply such as sand, rock, cement, etc., it is

required to carry out the test again to determine the suitable mix proportion.
6. When the weather changes (dry season, wet season) due to the change in

humidity, which has influence on density of sand, rock. So, it is necessary to measure, weight, adjust to keep the volume of concrete, thickness of concrete wall II. MACHINES, EQUIPMENT, TECHNOLOGY LINE 1) Concrete mixer
1. Using constrained mixer in the form of fixed bucket; intaking materials

through scraper system


2. After concrete has been mixed in the required time, concrete shall be

checked visually. If concrete meets the requirement, it shall be transported by trucks to charge in mold and carry out the centrifugal rotation process at slow speed at the same time. 2) Centrifuge
1. 2.

To spread concrete into tubular structures; To replace the concrete compaction process; centrifugal concrete can gain high strength: 400, 500, 600 ... 800 or higher;

3. Centrifugal speed should be increased gradually; 400 circle / min (at the

beginning and when intaking concrete then increasing the number circle to 600 circle/min, 800 circle / min, etc.. The maximum circle should not exceed 1600 circle/min for big sewer of D1200, D1500, D2000, not over 1200 rev/ph for the sewer of D1000 or less Centrifugation time depends on the condition of centrifuge, sewer mold, etc.. The operator should observe carefully to adjust the speed; time to have the highest quality products.
3)

Crane cranes are used to load, transport the molds to the position of concrete pouring, mold removing and transporting pipe to storage yard 05 ton crane for rotation beam No. 1 and 10 tons crane for rotation beam No. 2, No.3

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4) Boiler
a.

Boiler uses heat steam for steaming product:: Forced curing used to strip mold quickly, turnaround the use of molds in the shift of production and create condition to put the products on the market as soon as possible.

b. There are many types of boilers: blast furnace, lying furnace, etc., fuel: For

(fuel oil), coal, oil, Gasoil, Gas, fire wood; c. It is the under pressure-equipment, so operating procedures and safety should be executed strictly
5) Welder, steel strengthening machine, steel cutting machine

It is required to processing reinforcement according to technical requirement, ensuring productivity satisfies the continous operation of line . 6) Equipment Maintenance
a. Including regular maintenance during production and annual maintenance b. Before each production shift, the operator shall check the machinery and

equipment. They can test to check the safety of the device; if having any problems, they have to announce for shift leader, head of factory prior to put into operation. c. Every year, depending on the situation of production, the plant will maintain and repair some important equipment such as: bridges, boilers, centrifuges, concrete mixer. III. PRODUCTION ORGANIZATION 1) Production shifts Basing on production requirements under the contract and the capacity of the device. Production can be organized into 1 shifts, 2 shifts, 3 shifts or 1.5 shifts, etc. With normal conditions, the organization of 1 or 2 shifts is reasonable. 2) Steel cage handling a. Reinforcement shall be processed according to the design standards of the Company or the requirements from customers; b. Processing the sewer steel cage integrated with machines, fitting the flange and handling the range of similar products compatible with industrial production lines. c. The acceptance of steel cage can be conducted for each product, product batches, or selected products
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3) Mold preparation At least, Sewer mold needed to meet the minimum standard: no warping or twisting, the roller wheels contacting with the centrifugal, concentric wheel so that noise and bashes shall not appeared Mold for pouring concrete must be in the ready state: clean, cleaned anti-stalling agent, the stop end cleaned and assembled satisfying the standards. 4) Installing reinforcement into mold, assemling mold: a. Lower half of mold is placed in flat area, inserted into 2 sides avoiding rolling; cage transported by hand or bridges, installed in the correct mold b. The incorrect such as reinforcement contorted and located adjacent to mold, floated in center of the must be modified to meet the requirements before covering the top of the mold and continue to align, tighten the bolts; c. The two ends of the mold should be installed from the leakage of cement water during centrifugation; d. Bridges shall be used to transport the mold and steel cage beyond centrifugal gantry and prepare for cement loads and centrifugation 5) Centrifuge and concrete load: Starting up the centrifuge so that the mold rotates slowly; Inserting concrete into mold using the manual method; The load of concrete should be uniform from the center to the head of molds; Concrete loading should be continuously operated until the finish of definite concrete for each product The speed of centrifugation shall be accelerated so that it can keep the suitable speed and keep the definite time depending on type and condition of the mold product, centrifuge conditions. When inner side is in uniform and time of rotation at minimum, the rotational speed can be reduced centrifuge can be turned off 6) Heat Steam by steam It is considered as the curing process aimed to mold early, rotate the molds so that the strength of concrete is enough good to transport without any damages Heat steaming process must be started slowly from a low temperature (abstinent water vapor) to high temperature (increasing moisture) avoiding the cracking of surface
7) Mold removing

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Removing Mol shall be carried out after the concrete reaches a certain intensity (over 30% RTK) it usually happened when the heat rises at 80 0C for 2 hours, or after 48 h in the natural state. Removed molds should be located easy for cleaning and installation of reinforcing to cast the next product. 8) Production Crane Mold product shall be loaded into storage regulated for each product type IV. CRANE AND PRODUCT TRANSPORTATION 1) Product loading after molding
a. Mold product shall be loaded into storage. The classification based on the

right product for each type in each specific area, avoiding overlaying the products with different diameters because it is difficult to check the cargo cranes; The number of classes of products must comply with regulations to limit the
b. Cracking due to be weighed down by layers; c. It is necessary to transport the pipes promptly to ensure new products to be

molded 2) Product transfer


a. Product transfer to the regulated places aims to ensure product-arranging

areas after being molded and having enough time for the concrete-strength. In addition, the repair, acceptance of sewers must be finished hoisting the car to the site.
b.

Using the truck to transport pipe itself. Specialized hook shall be used so as not to crack reasonable batches. This avoids the waste of repair time, the unbeauty of products as well as bad influence on quality such as cracks along the tube, pipe batch, etc.

3) Arrangement of product on the road to the site a. Products are exported to the customer are the products which are executed the acceptance and ensured the concrete strength at least 70% of design strength ( steamed after 7 days; not steamed: after 14 days ) b. Inserting the two sides of the products, and use cable or rope to anchor the product avoiding rolling, moving in the transport process. 4) Withdrawal of products returned by customers

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a. When customers return products (due to manufacturing errors or defects in the hoisting, or the residual compared to actual requirements), the product must be withdrawn immediately on separate places in the company; b. Technical- Construction Department will report the returned products and deal with according to Regulations of company V. APPLIED STANDARDS Standards of centrifuge via TCXDVN 372:2006 under the Ministry of Construction issued on July 5, 2006 together with Decision No. 19/2006/QD-BXD: "REINFORCED CONCRETE PIPES FOR WATER DRAINING" (Reinforced Concrete Pipes for Water Draining) In accordance with industry standards: 22TCN 159 - round reinforced concrete of Installation. ; Reference to standards of American ASTM (American Standard Test Methods) PRODUCTION SAFETY
1) Safety of machinery and equipment

a. The machinery of production shall be checked and tested regularly prior to starting the shift; b. When equipment operator must have a certificate of examination of any machinery, the operators is allowed to use that equipment; the improper use of equipment or the hand over to the incapable individual shall be prohibited c. After each work shift, the equipment must be clean and ready for the next production shift; d. In case of failure in machinery that has not been redressed, it is necessary to record into diary and inform to previous shift leader and following leader and head of factory 2) Good execution of safety rules in production: Centrifugal Concrete workshop must comply with safety regulations in production:
Fire prevention for the workshop: water, sand, tank of CO clean Arrangement in the workshop; slogans focus on safety so that it is easy to find; Training and propagation of working safety for all employees in the factory; Labor insurance for all workers;

VI. MEASURES FOR IMPROVEMENT OF PRODUCTIVITY AND PRODUCT QUALITY ASSURANCE:

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1) Specialization of stages; 2) Increase of production capacity; 3) Increase the hours of working, shifts of working; 4) Product quality assurance; 5) Regular inspection and maintenance of machinery and equipment; Nha Trang, 01 May 2012 DIRECTOR OF COMPANY (Signed and sealed)

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