- REGION APPLICATIONS
1.1. The technological map is developed on the basis of methods scientific organization of labor and is intended for use in the development projects for the production of work and organization of labor during construction, reconstruction and overhaul highways.
1.2. The map is compiled for stabilization of the soil by the polymer "Stabilar" and "Stabilar E-95" (water soluble milky white thick liquid, non-toxic and neutral to the environment, reactive polymer emulsion is made on the basis of polymers and copolymers of various compositions). Stabilization Polymere "Stabijar" and "Stabilar E-95" is used in almost all soils: as in all kinds of sandy soil, and in clay soils, as well as the repair of roads disrupted coating, namely, stabilization sfrezerovannogo coating mixed with gravel base silted. soils, treated simultaneously stabilizer and an inorganic binder, It can be used in virtually all climatic zones, with any type of terrain humidification. Increased modulus of elasticity thanks compound particles coated cement ground with numerous polymeric chains. During the process of property is used to retain moisture. Protects compactor skeleton from the harmful effects of chemical components of soil, sulphates e.g.. Prevents capillary filtration and moving water. It reduces the migration of water - one of the main causes of wear of road surfaces. The total thickness of the stabilized soil 30 cm, including leveling layer (or strengthening layer) thickness 6 cm.
The scope of company cars adopted as the leading mechanism «Wirtgen», consisting of recycling WR 2500 supplied to the mixing installing WM 400 for soil stabilization operating speed 5 m / min, replaceable long zahvatki 600 m or 4000 m2 grounds.
Composition detachment auxiliary machinery includes: rollers BOMAG BW 161 AC, VP 200 и BW 216, grader DZ-122, universal machine KO806-06 for the transport of water, additive into the polymer (depending on the soil moisture is depend, Whether to dilute the polymer with water) and surface wetting, avtotsementovoz TC-12,
cementitious -rapredelitel, dump truck KAMAZ-55111.
1.3. Resaykler WR 2500 complete with the mixing installation WM 400 intended for crushing, Grinding materials of mixing soils, uniform introduction into a mixture of the polymer "stabilar" and "stabilar E-95" , mixing with inorganic knitting with the subsequent obtaining of fortified soil.
2. FOR ORGANIZATIONS TECHNOLOGY OF WORK PRODUCTION
2.1. Before the start of the WR recycler 2500 and mixing WM installations 400 the following work must be done:
· in laboratory conditions selected the optimal compositions of inorganic binder, determined the physical and mechanical properties of the fortified mixtures, which should meet the requirements of GOST 23558-94 "Mixtures of crushed stone-gravel-sand and soils, treated with inorganic binders, for road and airfield construction. A TABLE".
· cleared stump base, roots, shrubs;
· arranged leveling layer (or strengthening layer), the thickness of which is determined by the project;
· fixed pegged base to define the contour of the recycler.
2.2. Due to the lack of the recycler WR 2500 an automated tracking system for heading and elevation marks, the direction of its movement during the first penetration is fixed with pegs, located along the edge of the base in the direction of the machine. Pegs installed on a straight section of the road through 10 m, on curves - after 4 – 5 m. An engineer-surveyor takes part in the layout work.
For the next passes of the recycler, the reference point is the right regenerated strip edge.
2.3. To ensure continuous operation of the set of machines mobile mixing installation WM 400 should regularly be ensured by an abstract of inorganic binding (cement), The stabilizer of the soil "Stabilar" and "Stabilar E-95" with water. Total water tank capacity
– 8,5 t.
In this technological map, cement delivery is provided by TC-12 car cement truck with a tank capacity 16 m3 and speed of movement 40 kmh. Water delivery is carried out by a universal machine KO 806-06 with water tank volume 8 m3. Synchronizing the speeds of the work move of the Resykler and Auto -cement truck with a universal machine 806-06, Cement unloading, The soil stabilizer "Stabilar" and "Stabilar E-95" and water can be produced during the set of the kit.
2.4. A set of machines: recycler WR 2500 and mobile mixing plant WM 400 can be used for soil stabilization (increasing their bearing capacity), crushing solid materials (soil, stone materials, asphalt concrete), cold recycling of existing road clothes, when, after milling, all 100 % materials, and also for new construction, using the mixing method on the road.
Mixing plant WM 400 is an all -metal mobile structure, on which (Alternatively, you can place a cement bunker for storing cement 25 tn., system of screws and pipes with dosing devices for supplying cement control over materials consumption, etc.. provides the onboard computer system of the WM installation 400), capacity – for water 8,5 tn., Continuous mixer for the supply of soil stabilizer "Stabilar" and "Stabilar E-95" , directly mixer, The pump and hose for the supply of the stabillar and stabilar E-95 stabilizer to the distribution system of the WR respekler 2500. The performance of the stabilizer stabilizer supply mixer and stabilar E-95 – to 500 l / min.
Mixing plant WM 400 equipped with an engine internal combustion with a generator to provide electricity to electric motors augers, mixer, pumps and dosing devices. WM 400 does not have an autonomous engine for driving on the highway, but equipped with steering control for orientation in working hours. WM 400 driven by a WR recycler 2500 due to tough couplings, uniting machines into a single unit.
Good cement dosing can also be done cement spreader.
Water addition will depend on natural moisture content soil or materials and given density.
2.5. Resaykler WR 2500 Located on the welding chassis, An integral part of which is a water supply of stabilizer of the soil stabilizer "stabilar" and "stabilar E-95" . The wheels are fixed to the guides of the round section. The machine can rise by hydraulics and go down to these guides to the working and transport position. Each wheel wheel is in rotation by its hydraulic resort, which provides the machine with easy control and maneuverability. The recycler has four gears for working and transport modes of movement. Usually, the working speed of the recycler varies within 2 – 12 m / min, which depends on the type and strength of the regenerated soils and materials.
The main working body of the recycler is a milling drum diameter 860 mm. Tool holders are welded to the drum surface with round bar. The design of the tool holders allows, using locksmith tool, replace broken cutters on site. Recycler provided with four components of different cutters, intended for different types of processed material. Taking into account the height of the installed cutters, the diameter 1480 mm, what determines the maximum height of the milled layer – 500 mm. Special edge segments with incisors for clean walls milled strip.
The milling drum is enclosed in a sealed working chamber with variable volume, which improves the quality of grinding materials and practically eliminates release into the environment.
The working chamber is noise-insulated, which significantly reduces the level of noise generated by it. Milling drum width, but, Consequently, and regenerated strip 2438 mm. Behind the milling drum height-adjustable stripping blade, which improves quality stirring, creates an even surface of the milled material for recycler.
Resycler has two autonomous systems for feeding and distributing the entire width of the milling strip of the stabilar stabilizer "Stabilar" and "Stabilar E-95" . For the distribution of the stabilizer "stabilar" and "stabilar E-95", eight nozzles are located on the corresponding comb. WR recycler operator 2500 has the ability to block one or a group of nozzles from the control panel if necessary.
To ensure long-term and trouble-free operation recycler WR 2500 should be borne in mind:
– when the strength of stone materials is more 800 (in detail) cutters of the milling drum wear much more intensively;
– when operating the recycler in urban areas and on roads I and II technical categories, the thickness of the regenerated asphalt concrete layer is not must exceed 12 – 13 cm, if the thickness of the asphalt concrete layer exceeds specified values, then the excess of the layer in height must be cut off beforehand road milling machines;
– optimum height of the soil to be stabilized 25 – 30 cm;
– the maximum amount of injected cement is more than 14 % from volume of the stabilizing layer.
When the response passes of two or more stripes along the width of the base, adjacent stripes are blocked from 10 to 20 cm with the simultaneous deviation of one nozzle for the supply of stabillar stabilizer "stabilar" and "stabilar E-95" with repeated passage (rice. 2). Recycler stabilizes soil in one direction, and working speed, specified in this technical map, is 5 m / min. Reverse speed (idle) stroke is 18 – 25 m / min.
Resaykler WR 2500 and mixing plant WM 400 are served by two links, consisting of a driver of the VI category, assistant driver V category and two road workers III category.
2.6. After the recycler starts working, follow it with an interval 4 – 5 m along the regenerated strip (between the wheels of the recycler) at the same speed vibrating roller BW is moving 161 AS (roller weight – 9,5 t, when enabled vibrator – 27,2 t) for rolling in loosening mixture and preventing intense moisture evaporation, especially at elevated air temperatures. At the same time the roller prepares the milled layer for grading with a motor grader DZ-122. This technological operation is carried out in two passes of the roller along one track.
Length of the section of the regenerated base, based on timing the beginning of cement setting, usually amounts to 120 – 150 m (for this technical map received 120 m). With base width 7 m recycler makes three drills. The length of the interchangeable gripper can be 500 – 800 m (we accepted the capture length 600 m).
2.7. Upon completion of the stabilization of the soil, the stabillar and Stabilar E-95 stabilizer in one section Resycler moves to the next. The rolled base surface is profiled by the DZ-122 motor grader. Grading passes is completed after 8 passages of a car groom in the working move in one direction.
2.8. The base is compacted by the roller link, consisting of three mechanisms: roller BW 161 AS, pneumatic roller VP 200 (weight 8,5 t without ballast, with ballast – 18 t), vibratory roller BW 216. Movement pattern rollers are shown on (rice. 3). BW rollers compact the base first 161 AC and VP 200. BW roller 161 AC starts compaction from the right side of the road. For nim, to the left, with roller track overlap BW 161 AC on 1/3 and leveling spacing 5 m, the VP roller is moving 200. Sealing strip length 120 m (section length), rollers reversing back to the start of the lane (two passes on one track) and, moving to the base axis, continue to compact the base. At the same time, the roller Bw 161 AC on 1/3 overlaps the previous VP roller track 200. At this time the BW ice rink 216 continues to compact the base, focusing on its right edge.
After strip compaction, passing through the axis of the base, the rollers start working from the left edge in the same way.
Each skating rink performs 6 single track passes. Wherein roller BW 161 AC works according to the scheme: first pass – without vibrator, 2 – 6 passages – with vibrator on; roller BW 216 first and last two passes – without vibrator, third and fourth passes – with vibrator on. Required the number of passes is specified by a test compaction.
2.9. To prevent the formation of hairline cracks in summer period on the surface of the stabilized layer, ready-made additionally moisten the base with water at the rate 0,6 – 0,8 l / m2, and then roll on with VP roller 200 in two passes on one track.
2.10. Upon completion of the sealing of the stabilized layer of the base on its surface, it is forbidden to allow movement at the time of formation of the base with the soil stabilizer “stabilar” and “stabilar E-95” and inorganic binding (cement) minimally 24 o'clock, optimally 36 hours. Then, a rod of the bitumen emulsion is produced by the DS-36B auto-minister based 0,6 – 0,9 l / m2, after which the leveling layer is arranged (or strengthening layer) thickness 5 cm, Then, a rod of the bitumen emulsion is produced by the DS-36B auto-minister based 0,3 – 0,5 l / m2, Further, asphalt concrete coating is arranged on the prepared base. The thickness of the asphalt concrete pavement layer is determined by the project.
If, for technical reasons, the laying of asphalt concrete impossible, then the applied bitumen emulsion is a care product fortified mixtures. At the same time, a technological break is organized duration 7 – 10 days. During this period of time, the base must gain strength in compression not less 70 % from the project brand, after which you can to lay a leveling layer of asphalt concrete.
NOTE:
Polymer Stabler and Stabler E-95 » – can be used in all soils: as in all kinds of sandy soil, and in clay soils, as well as the repair of roads disrupted coating, namely, stabilization sfrezerovannogo coating mixed with gravel base silted. soils, treated with both a stabilizer and a mineral binder, It can be used in virtually all climatic zones, with any type of terrain humidification.
Stabilization soils are used in areas such as:
The technology is the process of thorough mixing of the soil with the polymer “stabilar” and “stabilar E-95” and inorganic astringent material (cement; M-400, M-500) followed by sealing.
Modern the equipment allows you to effectively carry out soil stabilization directly on site with high precision dosage of binding materials.
The dosage will be 4-9 % inorganic binder (cement; M-400, M-500) on the volume of the soil to be strengthened and 1,- 2,5 % Polymer Stabler and Stabler E-95 » .
To work with our polymer will need material (cement; M-400, M-500)
Laboratory indicators are made from calculation of the soil used.
Laboratories are done 2,7 and 28 day.
3. SAFETY
Persons not younger are allowed to work 18 years, past preliminary medical examination, trained in the appropriate program, passed the exams of the qualification commission and received certificates.
When the machines are running, unauthorized persons are prohibited behind in the direction of the car closer 15 m.
The rotor cutters should be changed after stopping. engine.
When performing work on the construction of the subgrade bulldozer guided by the following technical literature:
1. SNiP III-4-80. Construction safety.
2. SNiP 12-03-2001. Labor safety in construction. Part 1. General requirements.
3. TOI R-218-05-93. Standard instruction on labor protection for motor grader driver.
4. TOI R-218-07-93. Standard instruction on labor protection for skating rink driver.
5. TOI R-218-26-94. Standard instruction on labor protection for truck driver.
6. Spelman EP. Safety during the operation of construction machines and means of small mechanization. – M.: Stroyizdat, 1986. – 271 from.: