maintance for the concrete pole moulds

1 Operation Manual For Maintenance Man

1.1 The deformation of concrete spun pole moulds should be examined first (by the method of staying wire). If one or two sections of moulds is found deformation, open the deformed one.

1.2 The worn running wheel of concrete electric pole moulds should be processed with surfacing, polishing. If welding is released, it should be weld before the cleaning of the wheel.

1.3 Every lifting lug should be examined and replaced timely if found defective; the lifting hole should be enlarged if the hole is too small; the lifting rings of the upper mould and below should be aligned.

1.4 If the circular bar plate and longitudinal bar plate deform, they should be corrected and fully welded.

1.5 The connection flange should be examined to see if deformed or welding-released. The badly damaged must be replaced.

1.6 The damaged and missing links, bolts, heal blocks, cotter pins and locating pins should be repaired and replaced.

2 Operation Manual For Opening Mould, Straightening Man

2.1 The internal and external seam should be aligned along the cutting of the mould.

2.2 The seriously deformed flange should be corrected.

2.3 Make up the damaged or missing bolts, spacer, cotter pin and locating pins.

2.4 The cracked internal wall of mould or edge must be broke and welded, the surface should be finished finally.

2.5 The concrete pole moulds should be straightened with press machine.

3 Operation Manual For Mould Joining Man

3.1 The joint of the moulds should be polished with groove and smoothed so that the mould will keep straight and smooth.

3.2 The welding will not be done until the supporting plate is installed rightly. Weld and polish the worn inner hole of bearing plate.

3.3 Make up the longitudinal and horizontal plate, reinforced bars and straighten and weld the crooked.

3.4 The released weld of running wheel must be cleaned in the seam and not weld until the electric current is adjusted.

3.5 The cracked lifting rings should be placed where it is placed. The misplaced should be cut out and reinstalled. The smaller ring should be dealt with.

3.6 Cut out and change the damaged screw ear and make up the screws, spacer, cotter spins and locating spins. The drainage hole should be examined and dredged.

3.7 Examine, supplement and dredge the drain hole of the lower mould of bearing plate.

4 Operation Manual For Mould Cavity Repairing Man

4.1 The joint should be flat and straight and strongly welded. Weld the damage by hit, strain and valley by the mould edge again.

4.2 Supplement the missing screw, cotter spins, locating pins; examine the weld releasing of everywhere of the mould and the misplace of the flange of fixed part and repair them.

4.3 Examine the width of the seam of mould closing after the mould is closed and process it accordingly and weld the worn screw–socket.

5 Operation Manual For Running Wheel Changing Man

5.1 The height of replaced running wheel should be same and the joint seam of moulds should be less than 5mm.

5.2 The joint and flange in the fixing end should be examined to confirm the change.

6 Operation Manual For Lathe Worker

6.1 The dimensions of running wheel of whole mould should be totally same and the fixing ends and joint flange must be processed if found uneven and displaced.

7 Quality Track

7.1 The repair of the mould should be recorded according to the requirements of maintenance of mould and record card. The repairing parts and list of repair worker should be noted after the repair.

7.2 The whole mould should be examined by the repair group after the repair. If the self-repair passed, the quality inspector should be informed timely to recheck. The concrete electric pole steel moulds are not available unless pass the examination.

where to buy or to export the concrete pole making machine?

　Shandong CICQ Heavy Industry Co.,Ltd

　

　　Manager:Rebecca liu

　　Tel:0086 15318906257

　　Email: rebecca@sdcicq.com

        Skype:rebecca.liunn

we can supply client with :

1.Complete production line supporting machines selecting and all necessary backup accessories with high performance and good quality ;

2. Free Service of plant structure design and layout plan drawings and other necessary construction drawings and guidance of construction work,office, warehouse etc and related drawings according to customers’ requirements.

3.Installation and commissioning of all production machines as well as the workers training .

4. 24 hours tehnical support from engineers overseas .

raw materials for making concrete pole

1 Raw Materials

1.1 Steel

The main component of steel is iron, in which there is a little other elements such as carbon, silicon, manganese, phosphorus and sulfur. The amount of carbon has a great effect on the performance of steel. If amount of carbon is higher, the strength of steel will be higher, the rigidity is higher and the toughness is lower. If the carbon content is low, the strength of steel will also be low, the rigidity will be low, but the toughness and plasticity will be better. At present, the steel of concrete cement products business can be divided according to the chemical component into high-carbon steel C>0.6%, low-carbon steel C<0.25%, medium-carbon steel C 0.25%-0.6%. The low carbon steel and high carbon steel mainly be used in the structure of reinforced concrete and prestressed concrete. Recent years the carbon content of parent metal of prestressed concrete steel wire used widely in cement products is high, contains C0.7%～0.8%. After complicated controlling and heating process, the external surface has evolved into the spiral rib shape with good adhesiveness to concrete cement thereby increasing the grip of concrete. What's more, as the high strength and reasonable toughness, it has been greatly used in a variety of prestressed products production. By using it you can not only save a number of steel but also much money.
As the number of annular and longitudinal bar of pole has been stipulated by national standard GB4623, so regarding to the small diameter, low loading pole, when designing consumption of steel and choosing the materials varieties, the economical factor can be only considered. The practical experience has proved that the low carbon cold draw steel wire for low voltage, low loading capacity pole is most safe and economic. conversely, the pole with higher bearing capacity used in middle and high voltage transmission and transformation using high carbon steel wire is very safe and economic.

1.2 Usage of steel bar

In the past, when A3 steel is used widely in the concrete member, because of its good plasticity, toughness, weldability and safe usage, it is used widely and with a great number. As times goes on, people realize that the strength 650Mpa of cold-drawn low-carbon steel wire is far more than the strength 380MPa of its parent metal(A3). After a safe standard is stipulated, its usage especially in cement products has reached a fairly high and widespread level. With the learning of concrete and steel wire grip the cold-drawn spiral and cold rolled ribbed surface-deforming steel wire comes out. The application of new style reinforcing steel has a great effect on the improving of various performance indexes of concrete pole.

1.3 Cement
The production of concrete pole mainly adopts the technology of centrifugal molding. By the curing of saturated steam, the hydration reaction rate will increase and the strength which required by exerting pressure will be reached. So, better to use ordinary portland cement with the characteristics of fast condensation time, high early strength and application to steam curing.

1.4 Aggregate
It's better to use medium-coarse sand according to GB4623 for sand; rubble or pebble with the diameter of 5mm～20mm have been proved applicable to stones, and required to have good granular composition.

2 Concrete
The cement products are commonly made of ordinary cement concrete and composed of cement, sand, stone, water and admixture. In order to meet the production requirement of concrete pole, the concrete must have good workability, which effected by many factors such as cement variety, water, admixture, aggregate, environmental condition and technology condition and what is mostly used is to reduce the water consumption in concrete.

3 Centrifugal concrete
The concrete cross section meeting the requirement should display coarse and fine aggregate arranging evenly, without clearance and air hole; the nest paste of inner and external thickness is within 5 mm generally, and the thickest inner surface can exceed beyond 10mm; there is no sedimentation in centrifugal molding concrete products. The coarse aggregate presses against the external surface compactedly and closely. The paste content should be so full that the products will be smooth and artistic.

4 Centrifugal equipment and centrifugal technology

4.1 centrifugal equipment
The centrifugal equipment has a direct impact on the production quality of concrete pole. Actually, the certified centrifugal equipment is the combination of cengtrifugal spinning machine, spun concrete pole mold and good operation process.

4.2 centrifugal technology
In the centrifugal technological procedure the centrifugal time is generally set within 16min～18min. At present some enterprises making concrete poles has shortened the time to 12min which is the ultimate time of technological procedure. To get eligible products the strict process system must be built, and the high-speed shoule occupy 1/2 of the total centrifugal time. In order to decrease the centrifugal speed the accuracy of installation and adjustment of centrifuge spinning machine should meet the standard, the precision of pole steel mold meeting the standard to meet the requirement of high-speed running, increase the density of concrete and shorten the time of water excess water-extracting.
The centrifugal molding system is proceeding by low speed-medium speed-high speed.
Low speed(slow speed): when the slump of concrete is <6cm,the revolving speed is100rpm～120rpm, the spinning time is 1.5min～2min.
medium speed: In order that the equipement and products avoid the impact and vibration meantime ensuring that the excess water can be slowly drained thus the concrete will get compacted gradually. Spining time 1.5m～2min.
High speed: It's the molding speed during the revolving which ensures the excess water being removed with the full centrifuge and correct apprerance. Revolving speed>360rpm, time 7min～8min.

5 several common quality problems
bending : the bending degree can't exceed L/1000. The casuing reason includes that rigidity of pole mold is not enough, the strength and quality of concrete or the break of steel bar causes bending during manufacturing.
Wall thickness: the prestressed concrete pole with same specification has a best thickness. When the thickness increases, the cross section prestress decreases and the bearing capacity reduces.
Exposed reinforcing bar: inner expose and outer expose. The inner exposing reinforcing bar results from the the slump of concrete causing by the impact and vibration of reinforing bar. The outer exposing bar results from the binding of spiral reinforcing bar during the framework molding.
Thickness of protective layer: the prestressed steel wire can be exposed outside or it will speed the structure damage of concrete pole.
Joint close paste leaking: the paste leaking of seam close and end is a usual quality defect of apperace which can be avoided by improving the seam closing accuracy of mold, cleaing the concrete debris on the mold and filling the cotton rope, paper string in the commissure or oiling, controling the operation process strictly.

precast concrete pipe wire cage forming machine, key part of concrete pipe production line

1 Working Principle of Wire Cage Forming Machine for Concrete Pipe

This machine includes three plates, one is the main plate rotating, the second plate is pushing wire, the other plate is used to Diameter-transformed automaticly. The three plates are controlled and drove by its own motor and variable Frequency control system.

2 Features of Wire Cage Forming Machine for Concrete Pipe
2.1 Both flush joint cage, and Socket jonit cage, the angel of the bell can be adjusted.
2.2 PLC digital control system, and the Synchronous Ratio, Frequency converter, which promise the longitude steel bar straight, and the same span of the latitude steel bars.
2.3 One model machine can weld different diameter cages for the reinforced pipes, from 800-2400mm, length: 1-4meter, this machine is multi-function, and man-machine interaction, easy to operate and maintenance.

3 Technical Indexs of Wire Cage Forming Machine for Concrete Pipe

Model	DPM-1250	DPM-1500	DPM-2000
Diameter of longitudinal bars(mm)	12-32	12-32	12-32
Diameter of spiral bars(mm)	6-16	6-16	6-16
Distance between spiral wires(mm)	50-500mm	50-500mm	50-500mm
Max. cage diameter(mm)	1250	1500	2000
Min. cage diameter(mm)	300	400	500
Standard cage length(mm)	12000	12000	12000
Max cage length(mm)	27000	27000	27000

concrete pipe forming equipment supplier

We are a leading manufacturer of concrete pipe machines with more that 20 years' history.  By importing advanced technology and high-precision processing equipments,   Our products are famous for high produtivity ,  easy operation, durability and reliability. By now, our concete pipe machines have been all over the world such as Sudan, Nigeria, Kenyan, Ethiopia etc.  

1. Introduction of Concrete Pipe Mould

Concrete pipe mold falls into two types according to the way of connection of moulded drain pipes: rigid joint and flexible joint; pipe mold fall into three types according to the joint shape of shaped drain pipes: plain top, tongue and groove, bell and spigot; pipe mold fall into Ⅰ,Ⅱ,Ⅲ grades according the grade difference of external pressure load of shaped drain pipes

2. Features of Concrete Pipe Mould

2.1 The adoption of integrated design is reinforced design of leakproof slurry, no rough edges on which the mouth of pipe joints, easy mold-opening.

2.2 The friction rings in the molds are all made of 45 cast steel with durablity.

2.3 The steel plate we use is produced by Laigang which is one of the four major steel mills, and its abrasion resistance will be guaranteed.

2.4 The carbon-dioxide arc welding is applied into the all welding. The plasma cutting machine is used for cutting. Welding seam is smooth and nice, and the cutting seam is very exquisite. All above ensure the mold tough and durable and extend the service life greatly.

3. Technical Indexs of Concrete Pipe Mould

Mold Diameter(mm)	Cylinder Thickness	Hooped, Longitudinal Reinforcement
300~600	6mm	8mm×60mm
800~1000	8mm	10mm×80mm
1200~1500	10mm	12mm×120mm
1500~2000	10mm	14mm×150mm