Construction of hangars and stores

Frameless buildings

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FRAMELESS BUILDINGS (BAS)

 

Eldorado Group renders professional services for the design and construction of frameless and arch type pre-fabricated buildings. Besides   construction of hangars and warehouses, we successfully erect administrative, industrial and residential buildings utilising a metal frame. Construction of buildings and structures is carried out along with the installation of the thermal insulation made of polyurethane foam by way of pouring or spraying.

 

Gallery of sites……..

 

Frameless buildings for agricultural producers (BAS)

Warehouses and hangars for storage of grains, vegetables and mineral fertilisers and buildings for processing and storage of agricultural products.

 

We offer the following solution for storing grain (wheat, etc.).
Dimensions: width — 20 m, length— 50 m, height — 9 m Area 1000 m2.
Stored product total volume:

 

WHEAT — 3.060 thous. tonnes; RAPESEED — 2.720 thous. tonnes.

 

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3-hranenie-zernovyih  4-hranenie-zernovyih 5-hranenie-zernovyih

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We offer the following solution for storage of vegetables.

 

Dimensions: width — 18 m, length— 50 m, height — 8 m Area 990.0 m2.
Stored product total volume:
Apples 430-580 kg/m3 – 1.180 thous. tonnes; Cabbage 350-500 kg/m3 – 1.000 thous. tonnes;
Carrot 560-590 kg/m3 – 1.330 thous. tonnes; Onion 490-520 kg/m3 – 1.180 thous. tonnes.

 

Model-hraneniya-ovoshhey-fruktov  zerno-7-2

 

We offer the following solution for storage of potatoes.
Dimensions: width — 18 m, length— 50 m, height — 8 m Area 990.0 m2.
Stored product total volume:
Option 1 – 2.080 thous. tonnes;                                  Option 2 – 1.570 thous. tonnes.

 

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We offer the following solution for storage of FERTILIZERS.
Dimensions: width — 18 m, length— 55 m, height — 8 m Area 990.0 m2.

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Mineral fertiliser storage technology calls for increased requirements to construction materials that are primarily caused by aggressiveness of the environment created by fertilisers. For the safety of building structures, special additives (foundations, floors) are added to them and metal with special polymeric coating is used for manufacturing and construction of steel structures

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Warehouse facilities

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Buildings for the processing of agricultural products

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Frameless buildings for production and storage of products (БАС)

Buildings, warehouses and shops for production and processing.

Buildings for production

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Joinery manufacturing shop

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Фасад 7-1 – Facade 7-1  Фасад 1-7 – Facade 1-7

Facade finishing progress report

Pos. Building elements Type of finishing Note
1 Arch covering, end walls PAR and PAP profiles Metallic
2 Gates, doors Polymeric finishing coating applied at the factory Light gray
3 Wall base Plaster painted with organosilicone compound Dark gray
4 Windows PVC frame White
5 Metal parts Polymeric finishing coating applied at the factory Light gray

 

Technical information (steel structures, foundations, usable area of arch buildings)

 

Technical information

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Схема расположения элементов кровли – Roof element layout diagram

Профиль ПАР – PAR profile

Отв. ø250 – Openings ø250

Все необозначенные подвески считать ПД1 (см. лист 8) – All unmarked hanger supports should be considered PD1 (see sheet 8)

 

 

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Низ ПАР – PAR bottom

ПАП – PAP

Низ балки – Beam bottom

Лист 8 – Sheet 8

Ур.з. – Ground level

Все стойки считать С1 – All posts should be considered C1

Все балки считать Б1 – All beams should be considered B1

 

 

 

Steel structure drawings (КЖ)

 

Usable area of arch structures. Possible solutions.

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Technology advantages:

  • BAS are pre-fabricated structures with self-supporting arched shells. Due to their light weight, the steel structures do not require deep foundations and extra frames (supports, trusses or beams);
  • reduction of construction time (manufacturing and erecting of SS, S=1000m2in 7 days);
  • reduction of construction cost (minimum weight of the structure and lightweight foundation);
  • tightness (absence of bolts, nuts and sealing materials allows to operate the building without repairs throughout its entire service life);
  • a variety of designs, a possibility to adjust the radius of the arch panels (it allows to erect structures of varying width 6-28 m and height 3-12 m and of infinite length);
  • durability and reliability due to the use of galvanised thin steel sheets in coils of structural quality for the production of cold profiling panels with a thickness of 0.6-1.5 mm; the service life of buildings equal to the useful life the galvanised band itself (at least 25 years).

Production and construction works are performed by two MIC-120 and MIC-240 plants. Unique features of these plants are that they produce two different kinds of profiles:

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MIC-120                                                                                              MIC-240

(WIDTH 6M TO 18M, metal 0.7-1.0 mm)                            (WIDTH 16M TO 28M,metal 0.9-1.5 mm)

                                                                               

 

Production stages of construction:

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  1. Construction of foundation. Erection of a temporary frame;
  2. Alloy steel is placed into the panel moulding machine;
  3. 3,4,5,6. Profiles of required shapes and sizes are manufactured;
  1. Profiles are assembled into sections using the rounding machine;
  2. Sections are installed on the temporary frame;
  3. Sections are joined together using the rounding machine;
  4. The frame is fixed to the building;
  5. Construction of end walls;
  6. Structure concreting.

Comparison of prices on manufacturing and construction of steel structures.

Calculated using the example of 1000 m2 building.

Name Total weight
of structures,
t
Incl. the weight
of the housing
time
of production/
construction/
erection of SS
cost of
SS
Pros Cons
BAS
technology (20х50х9)
21.8 – UBM
240
28.9 – MIC 120
0 d/ 1.5 m/
7 d
 100 %  Price, construction time Minor
loss of areas for
rack storage
with rack height
of more than 3.5 m.
 LSTWS
technology
(20х50х4.5
wall)
 33.8   25.0 1-3 m/ 3 m/
1 m
  140 %  Saving
areas
in case of rack
storage
 High qualification
of erecting personnel, price, construction time,
low fire resistance
of the structure
 technology
of SS made of
ferrous metal
(20х50х4.5
wall)
 51.8   43.0 2-3 m/ 5 m/
2 m
 160 %  Saving
areas
in case of rack
storage,
possible
mounting
of a beam crane with
a slight
strengthening of SS
 Price, construction
time,
complex foundation,
requires
treating SS
against corrosion
and fire protection.

 

materialy-1materialy-2materialy-3

БАС – BAS

  1. PAR profile 1. PAR profile
  2. Wooden bar
  3. PU foam
  4. Zinc coating

 

 

LSTWS

  1. C-shaped profile 1. C-shaped profile
  2. Profiled roofing 3. Sandwich panel

 

Ferrous metal

  1. Steel post 1. Steel post
  2. Wind cross-bar 2. Wind cross-bar
  3. Sandwich panel 4. Sandwich panel

 Usable area of arch structures. Possible solutions.

yteplenie-ppu

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Modern and highly efficient thermal insulation: PU foam spraying

Classic structures made of traditional materials (bricks, blocks, concrete) are monumental, reliable and durable, but have one huge drawback – they do not possess a high level of protection against heat losses. Furthermore, because of the lengthy heating period and high and constantly rising prices for heating, low thermal conductivity of building structures comes to the fore.

We propose to solve this problem by using an external or internal insulation of building structures by spraying two-component PU (polyurethane) foam. The main “trick” of this insulating material is the lowest thermal conductivity rate compared to other materials currently used for insulation. Spraying or pouring is performed using the unique mobile high-pressure plant “GUSMER” H-II.

 

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Spraying technique

PU is a type of fabrication foam and the result of mixing two components: polyol and isocyanate. These compounds are mixed in the plant and fed from the pistol directly to the insulated (isolated) surface under high pressure. Due to a chemical reaction, foaming and solidification of the compound occur in a few seconds. The final formation of a protective surface occurs in up to half an hour. The thickness of a layer of PU foam is regulated by the plant operator when it is sprayed and is based on achieving the necessary thermal insulation and other characteristics. It should also be noted that when applying the polyurethane, no special preparation of the sprayed surface is required.

As a result, the customer receives the surfaces covered with a solid thermal insulation “blanket” without any cold bridges across the entire area. Roughness of sprayed surface does not have any significant effect on the quality of insulation due to lack of air layer between the material and insulated surface. Currently, none of the sheet insulation materials allow you to achieve such an outcome.

The existing variety of PU foams with different densities (35 to 120 kg/cubic metre) allows to decide specific (insulation) and complex (insulation + waterproofing + noise!!!) tasks in construction and can be used both in new construction and overhaul renovation, modernisation and reconstruction of buildings and structures. To summarise, we can say that this versatile material will serve you faithfully for decades.

 

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Operational specifications of polyurethane (PU) foam

PU foam is unparalleled among construction materials regarding thermal conductivity coefficient, waterproofing effect (for close-cellular PU foam) and neutrality to alkalis and acids.

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Advantages of sprayed PU foam:

  • Insulation and almost complete sealing of surfaces with a continuous layer without leakage of heat through cold bridges
  • Space savings due to reduction of the insulation layer while maximising the protective properties
  • “Dead” connection with sprayed bases of any surfaces, be it metal, concrete or board
  • The isolation of remote areas without losing the quality of works and without tedious finishing and fitting of materials to complex structural elements
  • Increase of the service life of buildings and structures up to 30 years
  • Fast application of the insulating material (up to 1000 sq. m. per day)
  • Safety and ecological compatibility of the used material
  • Increase of comfort by improving internal micro-climate
  • The insignificance of loads on supporting structures due to the light weight of the material

 

Thermal conductivity coefficients of the most popular building materials

Material Thermal conductivity,
W/mK
Relative thickness
of materials, mm
Polyurethane foam 0.025 40
Polystyrene foam 0.041 70
Mineral (rock) wool* 0.048 90
Wood* 0.130 274
LECA* 0.180 320
AE Concrete 0.220 400
Bricks* 0.450 760

It should be borne in mind that the thermal conductivity of wood, LECA and concrete blocks and bricks grows with increase of their humidity

Thus, specifications and properties of PU foam turn it to the irreplaceable construction material for complex protection of buildings and structures.

Practicality and low cost of polyurethane foam insulation allow to apply it at any sites that require high-quality thermal insulation. Due to its low weight per unit of area, the pressure on the building structure is minimal.

Polyurethane foam is a thermal insulator with the lowest thermal conductivity rate!

PU foam spraying across the inner area (including the load-bearing beams, frames and other elements) guarantees you a heat resistance around the entire perimeter of the building; PU foam isolates the entire internal structure without leaving junctions.

No expenses for additional fastening elements.

No need for subsequent water and vapour proofing and wind shielding – this is a substantial saving!

Long service life: a minimum of 50 years. By the way, the service life of the vapour-proofing material would not exceed 10 years and the cost of mounting such material would easily undermine the budget of even a large company.

Polyurethane foam is an excellent corrosion protection.

Due to the high strength, PU foam would increase the strength of the original structure.

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The use of PU foam in the industry is determined by the heat retention feature of such material, i.e. the ability to retain temperature conditions created inside the building (structure, premise) to the greatest possible extent. Thus, PU foam is used to complete two totally opposite tasks: heat (prevention of heat loss) and cold preservation.

Therefore, the industrial use of PU foam is:

Heat insulation of industrial refrigerators and freezers
The use of PU foam allows you to carry out heat insulation of industrial refrigerators in the shortest period of time regardless of shape and surface area.

Insulation (and optional waterproofing, if necessary) of warehouses, hangars, industrial buildings and structures of various configuration and functionality

Insulation of industrial storage facilities, tanks and other containers
Forms of such structures and technological application features often make it impossible to use insulation material other than PU foam

Thermal insulation for pipes

 

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During the construction of residential buildings using frame technology among other things, house owners are constantly looking for opportunities to reduce operating costs, most of which are costs for heating of dwellings. Architects and builders are aware of this and are working tirelessly to help house owners achieve this goal.

Traditionally, to solve the issue of thermal insulation in the industrial, administrative, agricultural and residential buildings, landlords and owners relied on the use of rock (mineral) wool. Mineral wool (fibreglass) insulation has become a construction industry standard for many years.

But progress does not stand still and fibreglass is no longer considered the most cost-effective of the existing insulation materials. Thermal insulation by spraying polyurethane foam is the most innovative, cost-effective and environmentally-friendly method of insulation.

Studies show that approximately 40% of energy is lost due to the free flow of air through the roof and supporting structures of the residential building. Gaps, small cracks and holes in the walls and roof are literally make money on heating fly in the wind. Application of PU foam as the insulation material allows to achieve a high level of room sealing – the heat will persist just as in a hot food container.

If we talk about the thermal insulation of the roof, PU foam is second to none among insulation materials. When insulating a roof, the application of polyurethane foam of a certain density and specific brand allows you to achieve the “3-in-1” effect: thermal insulation, waterproofing and vapour barrier. And smaller thickness of a sprayed layer compared to rock (mineral) wool allows you to use the space between rafters to place utility and communication elements, if necessary.

Also, do not forget about such a factor as quality of life. The application of PU foam as an insulation material improves the micro-climate in the rooms. PU foam does not cause allergic reactions and has no adverse effects on both human and pet health.

Important aspect: the effective service life of PU foam insulation exceeds 30 years.

Thus, thermal insulation of houses utilising the frame technology with application of sprayed PU foam is the best option in terms of saving heat, money, durability and ecological compatibility.