Technology permanent formwork

Technology permanent form "UB" ® for monolithic construction

Introduction
Construction technology with the use of permanent formwork UB "® (" Universal Power "®) is a cumulative technology, bringing together the achievements of all authoring" Company "Ark" in the industrial and construction sector for many decades.

The author of these promising developments - Mazur, Vladimir, who is also the founder of the "Company" Ark ", implements and promotion of new technologies in the construction industry. For many years, developers were able to implement virtually all of their know-how to perform restoration and construction work at many federal facilities and get a high evaluation of experts in the U.S., Russia and Israel. Customers, "company" Ark "became JSC" Mospromstroy "Administration of Moscow, Krasnoyarsk, Irkutsk, Orenburg, Krasnoyarsk Territory police, the Office of Railroad, etc.


Basis Technology UB "® - production of universal building blocks, such as thin-walled concrete panel of durable concrete. In the future, the technology of permanent shuttering UB "® has been expanded from the concept of" universal block "® system to the construction of the" UB "®, which combines many fundamental and recommended technological solutions to reduce the cost of foundations, floors, engineering systems, facade, and also includes support for the construction of a specially designed small-scale mechanization.

Technology permanent form "UB" ® was first used in 2005. in Krasnoyarsk in the construction of a private house, which was completed and commissioned in 2006.

In 2007, 2008, in Krasnoyarsk, on the initiative of private developers of social organization Kroo "My House" was established HBC and the project of building a small settlement.

Today, technology is "UB" ® is positioned in the market, "company" Ark "as a technology for social development. The technology offered by public associations in the form of rental equipment for the production of construction products and building a house, because special treatment is applied to pricing and the use of design that you can take it virtually any family with little income and to build a house in the idea of "Samostroya.
Technological heritage of technology "Rental Concrete" ®
To understand the essence of technology "UB" ®, is necessary, at least in general terms, to get acquainted with the technology "Rolled Concrete" ®.

For professionals the combination of the words "rental" and "concrete" may cause controversy, because concrete is plastic material, which could be laminating. Nevertheless, it is the word "rent" here is crucial. Rent a concrete mass by means of rollers and templates to seal the concrete, remove the pores and give the complex shape of the profile of concrete products. The principle of "rolled concrete" ® is patented (patent number 2,043,166) and is a unique technological solution that allows to obtain high strength and durability of concrete, as well as thin sheets of complex structure and its products. Know-how also extends to facilities that can roll the concrete and the concrete composition and the process of its preparation and installation.

The main feature is that the technology allows, without any special additives, plasticizers and seals, but only from the usual components (cement, gravel, sand and water) to obtain ultra-strong concrete. Thanks to technology it is possible to obtain high-strength concrete and the higher his mark on the frost resistance of cement at the brand. Example, if the cement grade 400, it is possible to obtain concrete grade 450 (class B35), and the test sample is performed after 300 cycles of frost and it is not destroyed. The observed trend of increasing strength due to the fact that when rolled compacted concrete and pores, which could crystallize during the freezing water and destroy the concrete - no.

Regulatory framework are the technical specifications (TU № 5714-002-10154329-94), specially designed primarily specialist of Institute of Design GOSSTROY Novatorovym Russia, where defined range of destination products: 1-2 grade building structures, operating conditions in areas with low temperatures of -50 ° C, various wet and thermal regimes, increased loads and in aggressive environments.

Practice and implementation of technology "Rental Concrete" ®
According to the specifications and achieved strength indicator, the production company had to find its application in the construction of complex engineering structures, bridges, overpasses, etc. So what happened when this technology was applied in the reconstruction of the engine rooms of the Krasnoyarsk hydroelectric power station, but market trends quickly changed and technology has its primary acceptance in the construction market in civil engineering, restoration, interior design and improvement.

An important prerequisite for entering the construction market by transferring rolled products rolled on products of complex profile, as well as adaptation of hire, not only for linear, but curved and rolled round on the principle of "the potter's wheel."

Rental carried out on the rolling mills and tables with rollers, and templates. The use of special molds for hire allows you to make very fine products with a complex profile, in which reinforcement is made, setting bonds and rolling elements of the castle.

Straight-line rent (fluted columns, cornices, plinths, steps with risers, handrails, bow string, and railings, curbs, etc.)



Rent on a "potter's wheel" (round columns, pillars, balusters, vases, fountains, bowls, etc.)



Curved iron (arches, fountains sides, curved eaves, steps, etc.)


Because the technology is "rolled concrete" ® allows thin-sheet products with a complex profile, all products are manufactured either as a lightweight "shell", which are faced with supporting structures or walls or as a fixed timbering, which is filled with a monolith.

Facing the cornice of the facade for the post-production


When mounted on the wall


Non-removable formwork for supporting columns


Ready cornice on the facade


Finished fixed timbering columns


Years of experience with thin-walled, of complex structure and the concrete panel products has become the main prerequisite for the development of a "universal power" as permanent formwork for the construction of private housing.

Technical parameters of the concrete panel UB "®
The main element of the system - universal power "UB" ® - is a solid concrete building block, performing simultaneously the following functions:
1. Fixed timbering to fill the walls of a solid monolith carrier.
2. Ready-made decorative (and protective) finish exterior and interior wall surface.

General view of Block "UB" ®:


Important features of the design unit "UB" ®:
1. The block is made in mold sets at once "collected" form, ie panels are not assembled by hand at a construction site, which guarantees the exact sizes and angles.
2. Block design allows you to fill a solid wall, carrying a monolith, hide supporting structures and utilities.
3. Unit operates as a fixed timbering in the process of building a wall. It is not a supporting structure, and remains after filling the monolith decorative wall finish.
4. The unit has reinforcement that connects the inner and outer side panels of the tie through the frame.
5. The side panel of the castle have a groove, allowing a fast and high quality wall surface.

General settings block UB "®:
Length - 800mm
Height - 500mm
Width - from 200 to 600mm
The area of the sidebar - 0,4 m?
Number of blocks in 1m.kv. Wall - 2,5 pc
Weight - 40-50kg
The thickness of the outer side panels - 30mm
The thickness of the inner side panels - 20mm

Sizes of blocks "BE" ®:


Each type of unit corresponds to a certain thickness of the monolithic wall:
Type number 2 - 200mm (150mm monolith)
Type number 3 - 300mm (250mm monolith)
Type № 4 - 400mm (350mm monolith)
Type number 5 - 500mm (450mm monolith)
Type № 6 - 600mm (550mm monolith)

More options block UB "®:
Material - Concrete
Grade of concrete on frost resistance - 450-500
The density of concrete - 2,4-2,7 tons / cubic meter.
Abradability - 0,54 g / cc.
The compressive strength - 45-50 mPa
Water Absorption - 5.3%
Strength of concrete in tension at a bend-5-6MPa
A eff estestvennyh radionuclides - 320

Acts of laboratory tests:
Cement grade 400
a. Acts of determining the quality of: sheet 1 sheet 2
b. Acts of determining frost: sheet 1 sheet 2
c. Acts of determining attrition: sheet 1
Cement grade 500
a. Acts of determining the quality of: sheet 1 sheet 2
b. Acts of determining frost: sheet 1 sheet 2
c. Acts of determining attrition: sheet 1

Color and texture
External sidebar block UB "® is as ready and the final decoration of the walls of the future. Color is achieved by introducing a concrete mix of land pigments and natural dyes, as well as by the addition of non-ferrous fractions of natural types of stone. Used: white cement, ocher, minium (red), chromium oxide (green), carbon black, marble, granite, dolomite, basalt crushed rock, etc.

Examples of colors and textures:










The unit can be made in mold sets an outside panel up or down. If the outer panel at the top, it is possible to obtain either a smooth or melkofakturnuyu surface type "Bouchard."



If an external panel from the bottom, it is possible to mold sets to lay the liner of a flexible polymer that can repeat the complex texture of natural stone or treatment.



The illustration below: left - natural Jerusalem tuff, right - the product is made of concrete with simulated Jerusalem tuff.



Maybe also use postprocessing, such as sandblasting, that allows you to discover the internal structure of concrete, showing inclusions of rocks with natural stone.


Colored fractions, which can be found almost anywhere in the


In the event that during the production process is difficult to keep control over the color of concrete composition and tonal distortions occur, we recommend using a front surface of the glaze to even out the color of the facade. Glaze is water dyes that can permeate the concrete surface to a depth of 0.5-2mm, without shutting its surface. Glaze - this is the most economical way to color concrete.

The illustration below is visible slice of concrete products, consisting of the underlying solid layer, the color layer based on white cement, marble and dolomite aggregates, as well as the final glaze surface water dye in 2 colors. During this processing small chips and cracks will not spoil the look.



Production of permanent form "UB"
Block UB "® is produced in a special mold sets consisting of multiple forms.

Mold sets consists of the following forms:
1. The basic mold sets - 1 piece:
2. Additional mold sets - 2 pieces:


Production unit UB "® conducted in such a way that made the day before the tie beyond the block for additional mold sets, which were later, are inserted into the main mold sets and made the block.

Manufacturing process unit "UB" ® (schematically):
For the production unit requires a desktop, which is going to mold sets.


Produced in part the lower (inner) panel unit


A mixture of colored gravel for production unit

For production units preparing a special hard plastic and concrete solution, where the inner panel using concrete grade M150-300, for the outer more durable concrete grade M300-650.



Start of production unit - installation solution for the lower panel


3. After which you install additional pieces of mold sets and inserted into pre-made clamping frame.


Installation of the trapezoid shape

4. Next is the upper panel of the unit, after which the block remains in the form of concrete to grab.


Connection tie frames with bottom panel




Start of production of the top panel, laying a decorative solution


Seal and create a decorative surface


5. After hardening of concrete (day or less), part of the mold sets disassembled and the block remains on the pallet until complete solidification.


6. After complete solidification of the block is removed from a pallet and stored on site for future construction.


Finished blocks with different textures and colors


Notes on the production units, "UB" ®:
In manufacturing unit is also reinforcing panels and tie framework eventually creates a single block of steel wire reinforcement 1-2mm in 5-6 strands in each direction.

1. For the production of 1 unit requires about 30 minutes of labor
2. For the solidification unit to parse the mold sets, and restart them on another pallet takes about 4-8 hours depending on the wet and thermal regimes. Thus, the mold sets can be restarted 2-4 times per day, respectively, will require 2.4 additional tray.
3. Ready to block removed from a pallet on the second day after manufacture and stored on site. To use it later in the construction, necessary to sustain it for at least 7 days after production.
4. The aggregate nominal figures for the production program:
a. Efforts to produce 1 unit - 0.5 persons per hour
b. Term of uncured concrete blocks - 7 days
c. Performance of a mold sets the minimum - 3 blocks per day
d. Resource mold sets minimum - 500 units to cosmetic repairs and checking the error of geometric dimensions
e. Weight of mold sets in the collection - 150kg, specific details about 15-35kg.
f. For continuous operation and optimal performance required an average of 10.6 mold sets.
5. Mold sets come packaged in special packaging:


Construction using concrete panel UB "®

The main advantages of the system
Unique block design allows you to:
1. Quickly and easily build straight walls
2. It is easy to ensure filling the walls solid monolith (!)
3. Hide bearing structures and communication within the walls
4. Do not use the expensive construction and lifting equipment
4. Significantly reduce the list of labor-intensive construction and finishing works

Building system "UB" ®
"Universal Power" ® is an essential element of building systems "UB" ®, but also offers additional solutions that ensure the quality, simplicity and reduce the cost of construction of buildings monolithic method.
The system includes:
1. The system of wall construction (using universal block UB "®)
2. The system shut-off devices (bearing and decorative items)
3. The system unit door and window openings (window units, salaries, window sills, thresholds, etc.)
4. System facades small architectural forms and elements (cornices, bases, etc.)

Fixed timbering also allows reinforcement of the walls and the erection of supporting columns, hide bearing beams and engineering construction within the casing.


Additionally, the blocks are used for doors and windows salaries, window sills, steps, basement slab, eaves, etc.


The wall heat
Thermal conductivity of the wall using permanent formwork UB "® directly dependent on the size of block" UB "®, and used a monolithic filler. The main thing that must be borne in mind - that the technology "UB" ® allows the use of a solid monolith and does not violate the integrity of the monolithic wall inside the concrete panel. Therefore, when calculating the thermal conductivity can be ignored most formwork, as later it will be only decoration of the total thickness of 50mm (20 +30 mm). Thermal conductivity, ultimately, will develop the type of monolith (foam concrete, claydite, arbalit, alumina, zemlebit, etc.) and monolithic wall thickness (from 150 to 550mm).

Nevertheless, we present a model calculation of thermal conductivity for the issuance of recommendations for the use of blocks "BE" ® in the Siberian region.

Dependence of the reduced heat transfer resistance fragment of wall blocks "BE" ® (400mm) from the thermal characteristics of the filler:



Analysis of the dependence of the reduced resistance to heat transfer, "UB" 600 mm thick on the thermal characteristics of the aggregate changes:



Explanations for the results of the calculation:



How to use these results:



Conclusions



Construction cost estimates
To learn about and compare you can see an estimate prepared by the project organization "KrasnoyarskGrazhdanProekt" to build a house, which has already been mentioned in this article (the original estimates, and compare the estimated additional payment).

Commentary to the budget calculation:

1. The original estimate was prepared under the option where the builder bought ready-made blocks "BE" and he built the house, filling the permanent formwork UB "keramsit.

2. Supplementary estimates included an option where the developer to independently produce blocks "BE" and instead use keramsit slag concrete.

3. In fact, instead of the cinder block was used arbalit, and the actual cost of building a home made 700tys.rubley.

Additional information about the rental cost, pricing for public projects, cost estimates, etc. are to be completed.