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GENERAL GUIDELINES FOR CALCULATING
TECHNOLOGICAL LINES AND THEIR ARRANGEMENT IN
BAYS
Islomova Nufuza Ismatjon qizi
Assistant of the Department of "Building Materials and Structures"
Jizzakh Polytechnic Institute
(+998888695880, islomovanufuza@gmail.com )
https://doi.org/10.5281/zenodo.16901444
ARTICLE INFO
ABSTRACT
Qabul qilindi: 10-Avgust 2025 yil
Ma’qullandi: 15- Avgust 2025 yil
Nashr qilindi: 19- Avgust 2025 yil
This article presents general guidelines for the design
and calculation of technological lines. It includes the
necessary calculations, technical requirements, and
practical approaches to improve the efficiency of
production processes and to ensure the optimal
placement of equipment within bays. In addition, safety
standards and the continuity of technological flows are
taken into account in the organization of technological
lines
KEY WORDS
Aggregate,
stand,
conveyor,
cassette,
line,
cyclograms,
mechanism, coefficient, beams,
trusses, arches, double-pitched
beams, formwork, reinforcement.
For the product manufactured in the workshop (or products produced at the plant), the
following main technological calculations are carried out:
Calculation of the number of technological lines based on the type of product and the
given production capacity of the workshop (plant);
Determination of the main specifications (number, dimensions) of thermal chambers
or autoclaves for heat treatment of the products;
Determination of the number of equipment (machines and aggregates) required for
each technological line;
Organization within the bays; execution of technological systems operations;
Optimization of machine and mechanism usage on the lines (cyclograms of the
technological system processes);
Rational organization of product repair, quality control, and shipment to storage.
The main technological equipment is installed in the casting workshop. The production
lines must fit into the bays of a standard production building with widths of 18, 24, or 36
meters and lengths ranging from 54 to 144 meters. The height up to the crane rail in the
workshop is 8.05 meters, with the distance between columns being 6 meters in the outer
rows and 12 meters in the middle rows.
The following stations are located in the concrete casting workshop: mold preparation;
concrete pouring; concrete compaction; demolding; repair; cooling; curing; product rework,
inspection, and shipment to storage stations; thermal curing chambers; intermediate storage
areas for reinforcement materials and assembly parts; and a mold cooling area.
When designing the technological process of the line, special attention should be paid to
the concrete pouring and compaction equipment. All other stations must be organized to
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ensure the rhythmic operation of the main process.
Selection of Technological Equipment.
Technological equipment primarily includes
the machines and mechanisms used in the casting workshop, such as concrete dispensers and
compactors, cranes, rebar processing machines, and vibrators. When selecting equipment,
preference should be given to the most recently manufactured and highly mechanized models,
as this enhances production efficiency.
In addition, the choice of equipment depends on the quality and type of raw materials as
well as the specifications of the final product. When selecting the machines and mechanisms
to be used, their quantity, capacity, and other technological characteristics must be
determined, either by calculation or based on special regulatory documents and tables.
The required number of machines and equipment is determined using the following
formula:
𝑵
𝑴
=
𝑹
𝟏
𝑷
𝑴
∗𝑲
𝒏
Where:
R1R_1R1 is the hourly productivity of the workshop (or line);
PMP_MPM is the hourly capacity of the selected machine (according to its technical
specifications);
KnK_nKn is the equipment utilization coefficient, taken as Kn=0.85K_n = 0.85Kn=0.85.
Organization of the Technological Process in the Workshop Line
. The technological
processes are divided into main and auxiliary parts. In the main processes, raw materials are
used to produce concrete mixtures, meshes, frameworks, and the final products themselves.
In the auxiliary processes, raw materials and products are transferred from one location to
another and are stacked as needed.
The key characteristic of a technological process is the execution of a distinct cycle,
during which the product moves step by step from one workstation to the next.
In the production of reinforced concrete products, the aggregate-flow method is widely
used. The overall technological process consists of separate operations. The placement of
reinforcement meshes and frames into molds, along with the pouring and compaction of the
concrete mix, is performed at a single technological station, while the curing of the products is
carried out in special thermal units (steam chambers or autoclaves).
In an aggregate-flow line, the following stations are typically included: mold opening
and preparation, concrete pouring and compaction, preliminary holding of products, and
thermal curing chambers (usually deep steam chambers are used).
Additional operations such as placing reinforcement into molds, cleaning, oiling, and
performing technical inspections are also integrated into the same line. These stations are not
technologically dependent on one another, and each operates in a cycle time of approximately
8 to 16 minutes. Products are transferred from one station to another using overhead or
bridge cranes.
The technological line of the aggregate-flow method includes the following components:
Molding aggregate (together with a concrete dispenser),
Machines for preparing and tensioning reinforcement meshes and frames,
Mold positioning units,
Thermal curing chamber,
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Stations for mold removal, product cooling, and technical inspection,
Stations for mold cleaning, oiling, and reinforcing,
Stands for quality control of finished products.
During thermal curing in the chamber, the temperature is maintained at 80–90°C.
The annual productivity of the line is calculated based on the type of product being
manufactured, the casting regime, and the working time of the casting station, using the
following formula:
P =
𝟔𝟎∗𝑪∗𝑽∗𝑻
𝑻
𝒔
Conveyor Method.
The conveyor method is an improved version of the aggregate-flow
method used in the production of reinforced concrete products. It is characterized by high
productivity and allows for full mechanization of all technological processes. In this method,
the product moves along with the mold through the technological stations.
The conveyor molds move along a rail track. Both continuous and intermittent thermal
units are used in conveyor lines. Continuous thermal units include horizontal slotted and
vertically positioned tower-type chambers. These are designed in a horizontal layout parallel
to the conveyor line.
Currently, continuous conveyor lines are widely used in reinforced concrete product
manufacturing. These lines typically consist of 6 to 15 stations, with a working cycle time of
approximately 17 to 22 minutes, and a movement speed of 0.9 to 1.3 m/sec. Conveyor lines
are generally designed for the production of products of the same type and shape.
The annual productivity of a continuous conveyor line is calculated based on the type
and specifications of the product, the casting regime, and the daily operation time of the
casting station, using the following formula:
P =
𝟔𝟎∗𝑪∗𝑽∗𝑻
𝑻
𝒔
Stand Method.
In the stand method, products are manufactured in stationary molds and
are cured directly within the same mold using heat treatment. All technological operations —
such as mold stripping, cleaning, oiling, installation of reinforcement frames, and concreting
— are carried out on-site at the stand.
This method is typically used for producing large-sized products (longer than 6 meters),
especially prestressed structural elements such as overhead crane beams, trusses, arches, and
double-pitched beams.
Depending on the production setup, stands are designed as:
Linear long stands (150 to 300 meters in length), or
Short stands, intended to accommodate one product along the length and 2–3 products
across the width.
Reinforcement tensioning is performed directly on the stand using built-in tensioning
devices. The movement speed of the concrete placing unit (concrete dispenser) is
approximately 1 to 2.5 meters per minute, and the complete rotation (or production) cycle of
a stand takes about 1 to 1.5 days.
For both long and short stands, the main parameters are:
The duration of the technological cycle, and
The time required for one complete production cycle of the stand.
The second key parameter is the number of products that can be molded simultaneously
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on the stand.
The annual productivity of a long or short stand is calculated using the following
formula:
P =
𝑽∗𝒏∗𝑪∗𝑩
𝑻
𝒔
Calculation of the Productivity of the Cassette Device
. The annual productivity of the
cassette device is determined by the following formula:
Р =𝑉∙𝑉∙𝑉∙𝑉
𝑉
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CERAMIC TILES USING WATER-SOLUBLE POLYMER. Central Asian Journal of Education and
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