This scheme is considered the simplest, air is discharged by bayoning concrete with a working part - most often with a round washer with a diameter of about 5-7 cm. You will also need a conventional construction perforator with a power of 1.5 kW and above, a piece of metal reinforcement of standard diameter with a length, sufficient to immerse the vibrating part in the solution. On the one hand, it is adjusted to the shape of the shank, on the other, it is connected to a ring or plate (cut from sheet steel with a grinder or finished products). The device starts up only after rigid fixation and checking of all connections. The desired effect is achieved due to the occurrence of a high-frequency reciprocating motion, a perforator launched in the percussion mode well penetrates the layers of the composition, regardless of its density and thickness.
A self-assembled vibrator for concrete mortar from a perforator is used for vertical systems (a nozzle with a plate is immersed in the mixture and distributes vibrations inside the formwork or fences) and for expelling air from horizontal screeds (a larger ring is placed flat). The recommended processing time with it is 2 minutes, after which it is transferred to a new site, all processes are carried out in manual mode.If necessary, the device is used as an external one, while the working part is applied to the formwork structures.
There are two options for achieving the desired result: connecting the tool with purchased ready-made factory attachments or making a vibration mace on your own. The technology in the second case is more complicated; assembly will require:
The main goal is to obtain a mace with an offset center of gravity, which is why a square rod is welded to the eccentric. All parts are usually matched to the dimensions of the shaft and bearings, if necessary, they are adjusted on a lathe. As a result, the central element should rotate freely and transmit vibrations to a piece of pipe. With a drill, such a nozzle is connected with a steel cable; to ensure the desired fixation, an appropriate thread is made at one end of it. All transmission elements are closed with flexible polymer tubes, the mechanism must be reliably protected from getting inside the concrete, periodically all joints are checked for sealing.
Such a device is recommended for layer-by-layer pouring of structures, the drill is inferior in power to the perforator. It takes about 20 seconds to develop one section, the calculated impact zone is usually 6-7 times larger than the diameters of the vibrating head. The pipe should be immersed in the solution smoothly and removed without jerking, after which the tool is transferred to an adjacent area. Compaction is considered successful when the monolith settles down by several cm and the cement laitance protrudes on its surface.
In addition to a drill and a hammer drill, other construction and household tools with a motor of the required power are used for self-assembly. They can be done:
When selecting the frequency and amplitude of vibrations for self-assembled deep vibrators, one should be guided by the instructions for electrical appliances, the type and expected mobility of concrete.
Low-frequency models (up to 3500 vibrations / min) are used when working with heavy mixtures, medium-frequency (3500-10000) are considered universal and compact different brands, high-frequency (over 10,000) are optimal when vibrating fine-grained compositions with high fluidity. The processing time is directly related to the same criteria: liquid solutions do not need long-term compaction, otherwise they stratify, air is expelled from heavy ones for at least 2 minutes.
There is a direct relationship between the volume of the concrete being compacted and the required power, with the risk of overloading, the rock drills and the drill will quickly fail. Hand-made devices are most often submersible and are poorly suited for large areas and monoliths. Moreover, in such areas, experts recommend using either presses or 2 vibration mechanisms at least, both for the purpose of carrying out work at the right pace in the event of a failure or overheating of one of them, and for reducing the time. When properly organized, they create overlapping areas.
On the basis of standard construction tools, it is more difficult to assemble a site vibrator, most often operating from a three-phase network and used to compact a large volume of soil, concrete mixtures and bulk materials during storage and transportation. Due to the need for high-frequency directional vibrations (most often circular), their assembly on their own without the presence of an induction motor is impossible.
VIDEO
For one-time processing of small structures, homemade products are more than enough; for permanent and professional use, a factory model is required. It is impractical to buy a drill or hammer drill on purpose.
Good afternoon everyone. Recently, at our construction site (I work as a foreman), cases of failure of vibrotips have become more frequent. Those. you turn on the electric motor (everything buzzes), but there is no vibration. you take the mace, knock it on something hard and. and there is no vibration, although the flexible shaft is fine. Went to the peasants in the locksmith, dismantled the mace. The design is simple, but the reason for the failure has not been clarified. Are there experts on such a tool?
Well, first of all, compare a working and a broken mace. Where is the dog buried
P_A_ wrote:
Well, if there are no apparent reasons, then maybe 2 options - the first is the cement milk got inside the mace, what to do is to tap it. it may be necessary to warm it up with a cutter - ONLY NOT THE THREAD - so that everything burns out, and the second option is the O-rings on the bearings dry up and the grease gets inside. what to do? yes, the same thing is good to clean everything, including soot, and it should work
Repair of submersible vibrators type IV-117A, IV-116A, IV-113, IV-75.
(As well as their imported counterparts).
Repair and maintenance of vibration technology and vibration equipment
Deep vibrators are designed for compacting concrete mixtures when placing them in monolithic structures. Also used in the manufacture of concrete and
reinforced concrete products for prefabricated construction.
Deep vibration allows you to remove air from the total mass of concrete. And also to compact the concrete mixture with a lower water content, which increases the strength of the concrete, increases its water resistance, frost resistance, wear resistance and reduces the hardening time. This process improves the adhesion of the concrete to the steel reinforcement and in the joints between fresh and hardened concrete layers.
The deep vibrator for concrete is designed to remove air from the concrete mass. Deep vibrator or "submersible vibrator ”, Consists of a motor, flexible shaft and vibrator head. Deep vibrators for concrete are simply irreplaceable on the construction site for monolithic work.
The deep vibrator (submersible vibrator) for concrete saves much time of work, compared to manual labor.
A deep vibrator (submersible vibrator) for concrete increases the fluidity of the concrete mass, which makes it possible for it to be evenly "placed" in the formwork.Not a single construction site where monolithic housing construction is used can do without this process.
High-frequency concrete deep vibrator can be used for compaction
plastic and inactive mixtures with a standard cone draft - 0.5 - 7 cm.
Deep vibrator device:
The vibrator is driven by a two or three phase electric motor. The vibrator motor is equipped with a squirrel cage rotor. The drive generates and transmits mechanical rotation to the vibrator hose.
The flexible shaft transfers the resulting rotation to the vibrator head.
For the convenience of carrying out monolithic work at the construction site, during the submission
concrete into the formwork, the flexible shaft for the vibrator is produced in different lengths.
And for different types and types of formwork, different diameters of the vibrator head are used.
Basic diameters Ø - 28, 30, 35.38, 45, 48, 51 and 76 mm.
Deep vibrators for concrete are equipped with electric drives with a voltage of 220V or 380V, with a power of 0.6-1.6 kW. flexible shaft from 3 to 5.8 meters long, as well as vibrator heads with a diameter of 28 to 76 mm for construction work in monolithic and reinforced concrete.
On request, flexible shafts up to 9m long can be supplied.
Here you can produce repair of deep vibrators , repair of submersible vibrators, repair and maintenance of vibration technology and vibration equipment , flexible shafts and vibrator heads.
Our company will carry out repair of deep vibrators Russian and foreign factories producing vibration equipment, such brands as: Masalta, Enar, Belle Group, JAECHANG MACHINERY, etc.
Deep vibrators for concrete are divided into the following groups:
They are all used by builders, but each group has its own pros and cons.
Also, depending on the type of engine, concrete vibrators are electric, gasoline and diesel.
The difference between a mechanical deep vibrator and a high-frequency one is that the mechanical motor can be supplied separately from the flexible shaft, and the high-frequency deep vibrator places the drive in the flexible hose itself. Also, as already seen from
Names, high frequency deep vibrators are equipped with a motor with increased frequency. For example, the average frequency of a high-frequency vibrator motor is 200 Hz, and a mechanical one is only 50 Hz. The high frequency concrete vibrator is also lighter in weight.
We produce repair of deep vibrators, repair of submersible vibrators, repair and maintenance of vibration technology and vibration equipment
The main reasons for the failure of deep vibrators:
1. Incorrectly selected or left standing frequency converter
The high frequency internal vibrator requires connection to a frequency converter. The voltage and frequency values on the transducer must match the voltage and frequency of the vibrator. The total current consumed by the vibrators (A) must not exceed the rated characteristics of the frequency converter. If the transducer is selected taking into account the possible connection of 2 or more vibrators, then add up the values of the force of all vibrators that are planned to be connected to the transducer. The model is considered to be selected correctly if the resulting sum is less than the output current of this model.
2. Incorrectly selected type of deep vibrator and type of mace for a particular product;
Choose a vibrator with a vibrator head diameter that best suits your product. Diameter less than 50 mm is suitable for small installations with very frequent reinforcement and narrow formwork (for example: columns, thin beams, thin wall sections, small foundations, floor slabs), diameters from 50 to 70 mm are suitable for laying supports and medium-sized slabs, diameter over 60 mm, suitable for large installations, foundations, support structures, bridges, dams and large-scale works.
The distance between the reinforcement rods must be at least 1.5 times the diameter of the vibrating tip.
3. The concrete is placed unevenly.
The concrete should be laid evenly, each layer should not exceed 50 cm in height. The vibrator should be immersed vertically in concrete at least 2/3 of the length of the vibrator head, it should also penetrate into the previously laid layer to ensure better adhesion. For minimum paving thicknesses, tilt the mace to maximize the contact area with the concrete. Submerge the vibrator at points about 8-10 times the diameter of each other.
4. Do not place the powered vibrator on hard surfaces as this could damage the internal parts of the vibrator head.
5. At the end of the work, the equipment is turned off in the following sequence: first, the vibrator is turned off, then the frequency converter. The vibrator must be washed and dried thoroughly, placed
in a suitable place so as not to severely bend or damage the cable and sleeve.
6. After every 1000 hours of operation, and in any case once a year, the vibrator must be inspected by an authorized service center.
If you have any problems during the operation of construction and vibration equipment, then our company knows how to solve it without problems.
We provide consultations on operation and maintenance
deep vibrators, submersible vibrators, manual deep
high-frequency vibrator, vibration equipment, vibration technology.
We also carry out maintenance and repairs:
Repair of deep vibrators.
Repair of submersible vibrators.
Repair of a manual deep high-frequency vibrator
Repair of vibration equipment.
Capital repair of submersible vibrators, deep includes:
1.Visual assessment of the equipment appearance
(melting, chips, damage, etc.)
2.Visual assessment of the technical condition.
4. Complete disassembly of the electric motor and device mechanisms;
5.Rewinding the stator of the electric motor (if necessary);
6.Rewinding the rotor of the electric motor (if necessary);
8. Replacement of cables (if necessary);
9. Repair of the eccentric (if necessary);
10. Replacement of the vibrator head (if necessary);
11.repair of the electrical part of the vibrator (frequency converter, etc.)
12.replacement of sealing glands,
13. Changing the oil in the oil chamber (if necessary).
We carry out metalworking works, including the manufacture of pulleys, etc.
Under the influence of a vibrator, even the thickest concrete solution becomes plastic and mobile.
Are you planning to perform concrete pouring work? For high-quality concreting, you need a deep vibrator - this is a special device that is immersed in concrete solution and creates high-frequency mechanical vibrations. I will describe how the vibrator works, and I will tell you how you can do it yourself.
Concrete mortar is a mixture of coarse and fine aggregate, binder and water. All components are made up of particles of different sizes. To obtain a high-quality monolithic concrete product, the compound particles of the solution should be tightly adjacent to each other, and there should not be voids and air pockets between them.
After pouring the mortar into the formwork, a deep vibrator is immersed in it, while the following processes occur:
Increase in ductility: High-frequency vibration is transmitted to solid particles and causes them to vibrate continuously;
This contributes to an increase in the mobility and fluidity of the concrete solution, so it flows well even into the deepest and narrowest places of the formwork.
Concrete compaction: Moving particles under their own weight are tightly pressed against each other and against the details of the reinforcement strapping, which increases the density and strength of the concrete product;
An increase in density can be seen with the naked eye when, when the vibrator is lowered, the concrete begins to decrease in volume before our eyes.
Removing excess air: Due to vibration, heavy solid particles under their own weight fall down, and lighter air bubbles rise up and are removed from the concrete mixture;
Thus, concrete borehole vibrators help to reduce the porosity of concrete, and at the same time increase its frost resistance, water resistance and crack resistance.
To properly compact the concrete, the vibrating nozzle must be periodically removed from the mortar and moved only vertically up and down.
The device of the concrete vibrator is very simple. It works on the principle of eccentric imbalance and consists of three main mechanisms:
Drive mechanism can be gasoline or electric.In private construction, a deep vibrator is usually driven by an electric motor, a powerful electric drill or hammer drill;
A coupling is installed on the output shaft of the drive for connecting flexible shafts with a vibration nozzle.
Flexible shaft serves to transfer torque from the drive mechanism to the vibration attachment:Manufactured from a rigid metal cable enclosed in a flexible outer sheath;
The length of the shaft is selected so that it is 800-1000 mm longer than the deepest place in the formwork.
Vibrating attachment or mace serves directly to create mechanical vibrations:The body of the mace is made of stainless steel in the form of a hermetically sealed glass with a diameter of 40-60 mm;
There are two rolling bearings in the lower and upper parts of the glass;
A steel shaft rotates freely in the bearings, which is connected to a flexible drive cable;
An eccentric imbalance with a displaced center of gravity is fixed on the shaft, therefore, with fast rotation, the mace begins to vibrate at a high frequency.
The figure shows the internal structure of the vibrotip of the deep vibrator.
Construction vibration tools from the German company Wacker Neuson are considered the most reliable, but their main drawback is a rather high price. At the same time, you can make the simplest deep vibrator for small volumes of concrete in your home workshop.
There are three types of vibrators for concrete, but below I will talk about making only the deep type.
To make a high-frequency vibrator, you need a set of locksmith tools, a powerful electric motor and a pair of bearings, and you can find the rest of the materials among the scrap metal:
Metal locksmith workbench;
Two hammers weighing 200 grams and 500 grams;
Powerful locksmith vice;
Pliers or pliers;
Adjustable gas wrench;
Flat and curly screwdrivers;
Measuring tools (ruler, vernier caliper).
Powerful drill or drilling machine with 3-16mm drill set;
Grinder with cutting and cleaning discs for metal;
Grinding machine with emery stone;
Welding machine with 3-4 mm electrodes.
Single-phase electric motor with a power of 0.75-2 kW, with a rotational speed of 1500-3000 rpm.
A section of a thick-walled stainless steel pipe with a length of 300-500 mm and a diameter of 40-60 mm;
Steel bar with a diameter of 10-16 mm and a length of 300-500 mm - 2 pcs.;
Rigid steel cable with a diameter of 6-8 mm and a length of 1-2 m (you can use a piece from a plumbing cable, as in the photo on the left);
Outer sheath for cable (high pressure reinforced rubber hose can be used;
Bearings with an outer diameter equal to the inner diameter of the pipe - 2 pcs .;
Metal bushings, threaded cups, fasteners and other hardware.
A powerful electric drill or hammer drill can be used as an electric motor.
The concrete compacting mace is manufactured separately and is connected to the electric motor via a flexible drive shaft. This allows not only to increase the working length of the tool, but also to reduce the return to hands from mechanical vibrations that create high-frequency deep vibrators.
Outside on a stainless steel tube, cut threads on both sides;
Press in one rolling bearing from the bottom side;
Screw a cap plug with a rubber gasket onto the lower end of the tube
Pick up a steel bar of such a diameter that it fits snugly into the inner race of the bearings;
The length of the bar should be 50-60 mm longer than the length of the outer tube;
Take another piece of the same rod;
Its length should be 20 mm less than the distance inside the tube between the bearings;
Weld the short bar laterally along the axis to the long shaft so that, after being installed inside the tube, it is in the middle between the bearings.
Insert the shaft with the welded eccentric into the stainless tube;
Press the lower end of the shaft into the lower bearing;
Put the upper bearing on the protruding end of the shaft and press it into the upper end of the tube.
Attach a thin-walled steel tube to the protruding end of the shaft;
Insert and rivet a flexible drive cable inside the tube.
Fix the outer sheath of the cable with a clamp to the upper end cap;
Pull the cable through the entire length inside the outer shell;
Screw the upper end cap with the fixed shell through the rubber gasket to the mace body.
The flexible shaft must be connected to the drive in such a way that its outer shell is rigidly fixed to the motor housing. The inner cable must be connected to the motor shaft so that, after switching on, it rotates with it. Below is the instruction with pictures:
Pick up a thin-walled metal pipe, inside which the motor shaft can freely pass;
Weld a wide washer with mounting holes to it from below;
Cut several radial segments on top of the pipe;
Fasten the flexible cable firmly to the motor shaft;
Put the pipe on the cable and fasten it with screws to the engine body through the holes in the washer;
Bend the cut petals on the pipe slightly inward, and insert the outer sheath of the cable between them;
Squeeze the petals from above with a metal threaded clamp.
Make a bracket from a steel plate and a piece of pipe, as shown in the figure;
Clamp the outer sheath of the cable with the bolts inside the pipe.
This bracket allows you to attach a deep vibrator to a conventional electric drill using the plastic side handle that is supplied in the kit;
Before installing the bracket, the free end of the flexible cable must be clamped in the chuck.
VIDEO
You were able to see that making a deep vibrator yourself is not difficult at all. I recommend watching the video in this article, and leave all suggestions and questions to me in the comments.
The device of a vibrator for concrete is designed to compact the prepared concrete mixture, collapse of air bubbles, remove excess liquid, to increase its strength. With the naked eye, you cannot discern the initial content of a large amount of air in the solution.
In a freshly prepared mass, as in the photo, from 10 to 45% air can be present. Why does this small, air bubble lead to loss of strength and durability of concrete masses? It would seem that the mobility of the mixtures, their uniform laying depend on air bubbles - from where then cracks appear on a flat concrete surface.
Mixing any concrete mixture is not complete without air entrainment into the solution.It is the air that determines the quality characteristics of the concrete solution, including durability.
Simple ingredients for the preparation of a mixture (cement, sand, gravel, water), sand and gravel serve as aggregates, cement as a binding material. Sand is one of the simplest air-entraining fillers when mixing ingredients, although experienced concrete workers expand this list somewhat.
Air bubbles have the ability to float upward and lose their vitality, unless they decrease in size;
By and large, the total proportion of air in concrete is not a consumer important characteristic of frost-resistant properties, but an important sign of concrete durability is the distance from one bubble to another, and the smaller it is, the more durable the concrete;
To saturate the mass with air:
Dosing of fillers is applied, but strict control is carried out so as not to shift additives;
The higher the draft of the cone, the more air entrainment will be;
The instruction regulates the use of a certain amount of large fillers, increasing the particle size of the additives, reducing the air content;
Small fillers not only help entrain air, but also retain it;
An increase in temperature reduces the amount of air in the mixture;
By increasing the speed of mixing the ingredients, the volumetric mass of air increases and there may come a moment when the permissible rate is exceeded. Therefore, there are speed recommendations on concrete mixers;
Increasing the mixing time may reduce the required amount of air;
Vibration processes reduce the volume fraction of the air mass, transforming individual, large bubbles into small ones, and this process deserves the utmost attention.
As noted, voids in the concrete mass during the pouring of foundations, reinforced concrete structures, and columns negatively affect the quality of the monolith. The concrete vibrator that appeared on the construction market turned the task into a technological process called vibration compaction.
It is performed by special devices. The main characteristics and coefficient of shrinkage of concrete depend on the thoroughness of this action. The compaction process is carried out by workers, treating the surface with their own hands or with the help of mechanical devices.
The manual method used in private construction saves the developer's money and is performed with the following tools:
Manual compaction is important in cases of processing a small amount of mixture. They are also used for compaction with scrap, rammer, shovel;
The more the building mixture is tamped, the slower the moisture leaves the structure, which improves the hydration indicators;
In industrial construction, a concrete vibrator solves the problem; in the private sector, they do it with bayonet;
Attention: After tamping, a dense screed is more difficult to cut and drill, therefore drill bits with diamond chips are used, ordinary drills instantly "fly".
Bayonetting is performed with a metal rod (a reinforced rod is suitable) weighing no more than 4 kg;
The rod must have a rounded end to "pierce" the concrete;
This process compacts crushed stone, displaces air, excess liquid, therefore experts advise to bayonet the entire surface of the solution;
The mechanical method of compaction is used when filling large volumes of mortar:
The video in this article demonstrates special vibrators used in the modern construction industry;
All basic models of structures use an electric motor, a transmission mechanism, an oscillation generator (eccentric);
The rotating eccentric transmits the given vibration frequency, 3 types of vibrators are determined by the transmission methods;
Submersible, for compacting the mass of concrete in depth ... The working mechanism of the vibrator is placed inside the mortar laid in the formwork;Vibrating presses used on horizontal floors, slabs; External vibrating presses when formwork elements serve as working surfaces.The processes are carried out with special devices:
Hand-held vibrators for concrete are surface, in a special case - vibrating screeds, allowing only the top layer of concrete to be compacted. Builders use them for thin concrete pouring: on floors, foundations for laying tiles and roads;
Vibrating devices for internal compaction, here the vibrating screed for internal compaction is one of the most effective mechanisms when compared with others. It is used in hard-to-reach places;
Vibrators mounted on a wooden formwork or mold, securely fixed to the surface. The cement slurry is compacted by vibrations transmitted from the device. Sometimes it is necessary to perform concreting of an unusual shape. In this case, the deep vibrator, which is installed directly into the mold, is simply irreplaceable;
The processes taking place in concrete solutions are presented below.
Vibration compaction can be carried out with portable and stationary devices;
When working on prefabricated reinforced concrete structures, the use of portable mechanisms is limited;
The concrete vibrator nozzle has a tapered or cylindrical shape, it all depends on the objects of compaction;
For mixtures with a normal density of reinforcement, a device is used, the cylindrical part of which is called a "vibration mace";
In a structure where the density of the reinforcement is increased, a narrowed tip is used for vibration, it is also called a "vibration bayonet".
Vibrating pads are used in reinforced concrete plants on an industrial scale, when the work is organized according to special schemes;
According to the principle of operation, they are pneumatic, electromagnetic, combined;
Compaction is not so popular among specialists, although its effectiveness is noted. The strength of the mortar with a small consumption of cement increases significantly with this method.
The price of pressing strongly "bites", so it is neglected in private construction. Compaction of concrete solution is carried out at a pressure of 10 MPa and higher. Presses with this capacity can be seen in shipbuilding.
Is pressing really not used in private construction? There is no definite answer to this question;
Using a vibrator for concrete floors, pressing is applied as an additional load;
The modern market has flat and profile dies;
The use of profile dies is relevant where the products are given the necessary configurations, and then pressing is replaced by stamping;
In the manufacture of concrete panels, staircases, hollow blocks and other elements from mortars;
Another type of pressing is transformed into rolling;
The pressure is carried out by the roller, which saves energy;
Attention: The disadvantage of this method is the possibility of displacement or even rupture of the solution with a roller
Evacuation dilutes the air and under strong pressure all excess is removed from the mixtures. Effectively vacuuming works when constructing concrete floors;
Centrifugation increases the density of the ingredients and about 30% moisture comes out of the solution, which increases the strength of the concrete mixture;
The technology is used in the production of power transmission line poles, pipes, racks.
VIDEO
These devices are used to compact concrete solutions, as usual, they do not do without repair. Repair of a vibrator for concrete is relevant mainly for equipment of submersible models. They contain consumables - tips and flexible shafts are more likely to fail.
When working, it must be remembered that the pouring of the foundation must not be stopped, therefore it is necessary to constantly monitor the operation of the vibrator in order to avoid breakage. The foundation is poured from a low height in order to avoid unnecessary entrainment of air masses.
Video (click to play).
Do not keep the vibrator in one place to avoid delamination of the concrete. In order to prolong the life of the factory vibrator, it is not recommended to run it "idle".
