• 28.04.2017
Ceramic Construction Materials Production Plant in the Bolivarian Republic of Venezuela

The plant is intended for the production of ceramic building materials by the method of plastic molding.

The annual program is 25 million pieces of blocks with dimensions of 15 × 20 × 30 cm .

Architectural Planning Solutions

The main factors that determined the layout of the site were:

  • configuration and location of the projected area in the city system and at the intersection of the highway and the street of the industrial zone;
  • functional and technological purpose of production;
  • space-planning decisions of buildings and structures;
  • features of the existing terrain.

Construction of a Plant for the production of ceramic building materials shall provide the need to obtain a sufficient amount of building materials to meet the demand for the construction of housing and other facilities on the territory of Latin America.

The project provides a clear separation of the projected territory according to its functional and technological significance into:

zone near the administrative building with a shop, transformer substation and technical rooms, where the main pedestrian flows are oriented. Places of short-term rest, decorative elements of accomplishment are located here;

main production area, including the industrial building;

–  warehouse area, which includes two subzones:

  • clay warehouse, which is a tent with a hard roofing, connected with the industrial building by the reception unit and having a stock of clay for the rainy season. The clay warehouse has an elongated shape and is located in parallel to the industrial building. The clay is supplied by road from the south facade.
  • An open warehouse for finished products is located along the east side of the site. The loaders unload the finished products from the industrial building to an open warehouse and then it shall be shipped by motor transport outside the plant.

zone of auxiliary buildings and structures:

  • carport garage located through the passage from the western side of the industrial building;
  • two fire tanks and a water well for technical and fire water supply in the north-eastern part of the site;
  • gas control point, which is located in the southeast corner of the plant;
  • checkpoint at the entrance of the Plant.

parking zones are:

  • parking of personal vehicles of employees for 10 places in front of the administrative building;
  • cumulative area of trucks for 5 places in front of an open warehouse of finished products;
  • parking of service vehicles for 15 places in the north-western part of the site.

There is also a parking place which fits the length of a long truck in front of the checkpoint and the gate before entering the Plant.

zone of perspective development of the enterprise is represented by two sites in the eastern part of the projected territory, which are characterized by a steep rise of the existing relief and require the development and planning.

Main technical and economic indicators

Name Unit of measurement Indicator
1 Area of the territory (in the fence) ha 7.79
2 Building area ha 4.18
3 Coating area ha 2.29
4 The area of greening ha 1.32
5 Building factor % 54.00
6 The area of prospective development ha 1.74

 

Production Technology

The plant is intended for the production of ceramic building materials by the method of plastic molding.

Annual program – 25 million pieces of blocks with dimensions of 15 × 20 × 30 cm .

The need for raw materials for the annual program (including 5% of waste): 162 750 tons or 102 000 m3.

The plant is intended for the production of ceramic building materials by the method of plastic molding.

The production of ceramic materials consists of the following basic technological operations:

  • Clay preparation
  • Preparation of ceramic mass and molding products
  • Drying products
  • Roasting products
  • Separation of products from the kiln cars and its packing for transportation

Architectural and Construction Solutions

The project provides for the construction of: an industrial building, an administrative building with a shop, a clay warehouse, a carport garage, a checkpoint and other auxiliary buildings and structures.

The industrial building is a one-storied building with dimensions of 108 × 240 m with a net of columns (24 + 30 + 24 + 30) × 6 m.

The height to the bottom of the rafter beams is variable from 10.8 m to 13.5 m. The following sections are located in the building: primary mass preparation, secondary mass preparation, molding, drying, furnace, unloading and packaging, as well as a transformer substation. Building in axes

A-B is equipped with an overhead crane with a lifting capacity of 10 tons. The external walls and the covering of building are projected from three-layer metal panels 50 mm thick with “ISOTEX” material filling.

The windows and doors are made from aluminum alloys. Gable roof. The gates are sectional made of steel with wickets. Drainage from the roof is organized outdoors. Natural lighting is provided through the windows and strip lights. In the upper zone of the wall fencing louvered grilles are provided for natural exhaust.

The production building is designed in a metal frame using welded I-beams of variable length along the section. The stability of the building frame is provided in the transverse direction by the rigidity of the transverse frames, in the longitudinal direction by a system of vertical and horizontal connections and struts.

The clay warehouse with a reception unit is presented by a tent 36×240 m in size with a net of 36×12 m columns. The height to the bottom of the roof beams is variable and ranges from 10.8 m to 12.9 m. The cover of tent is designed from metal profiled sheet. The roof drainage is organized outdoors. The tent surface is designed using welded I-beams of variable cross-section along the section length. The stability of the tent frame is provided by the rigidity of the transverse frames and the system of vertical links.

The administrative building is a separate building with dimensions of 30×15 m with a grid of columns (6 + 3 + 6) x6 m. The height of the floor is 3.3 m. The building houses: the wardrobe units with shower rooms for 196 people taking into account the development prospects, ventilation camera – in the basement; the main lobby, director’s office, meeting room, a shop, a buffet for 20 seats, first aid room – on the first floor; office space, a dining room – on the second floor.

Exterior walls are designed from three-layer metal panels with the thickness of

50 mm with “ISOTEX” type of filling material. Windows, stained glass windows, doors are made from aluminum alloys. Drainage from the roof is organized outdoors.

The administrative building is designed in a metal frame made of I-sections profiles. The stability of the body is provided by a system of vertical connections.

Sanitary service is provided for the entire payroll (132 people) and provides a full range of services.

The carport garage is designed of metal structures with a plan size of 18.0×54.0m and the checkpoint is made of metal structures with a plan size of 5.0×6.0m.

Main Construction Indicators

Name of construction Area
Industrial Building
Building area 25920 m2
Total area 25900 m2
Construction volume 351216 m3
 
Administrative Building
Building area 468 m2
Total area 1451 m2
Construction volume 5447 m3
Clay Warehouse
Built-up area 9840 m2