info@gerb.com
Solutions for Block Making Machines
Solving neighbour complaints through effective vibration isolation in concrete block manufacturing.
Concrete block making machines are the heart of every concrete block factory. Their performance and precision significantly determine the quality of the concrete blocks produced. The high compaction forces generate strong vibrations that can affect not only the machines themselves but also surrounding buildings. Due to earlier foundation designs, elastomeric materials are almost exclusively used for vibration isolation in new designs for block making machines. This poses a considerable risk of resonance effects in the machine‘s operating frequency range. Significant vibrations occurred in a newly constructed concrete block factory, which were even noticeable in the adjacent residential building. GERB was called in to develop a solution that would ensure troublefree and long-term safe operation of the plant.
Technical Challenge
The block manufacturing machine caused considerable vibrations in its operating frequencies between 25 Hz and 50 Hz. Elastomer plates were originally chosen as the mounting solution, which led to the following problems:
- High vibrations affected manufacturing tolerances, leading to production deviations.
- Complaints from neighbours about clearly noticeable vibrations on glass false ceilings in residential buildings.
Limited space in the already completed plant made it difficult to implement a new storage solution.
Solution
GERB developed a tailor-made concept to provide a sustainable solution to the vibration problem.
The use of steel springs in combination with VISCO® dampers has resulted in a significant reduction in vibrations. The bearing frequency was set to 3.3 Hz, although replaceable spring elements allow a further reduction to 2.5 Hz. In addition, a special construction method has reduced the surrounding air gap to just 100 mm. GERB took over the planning from the initial feasibility studies to the implementation planning of the foundation block pit, the delivery of the elements, the assembly and the vibration measurements carried out after completion.
Did you know?
Structures that are supported directly on the subsoil or additionally mounted on a continuous elastic layer frequently exhibit resonance effects in the range of 10–50 Hz. Even with detailed geotechnical investigations, a large scatter in the dynamic soil parameters remains, further amplified by variations in soil moisture and groundwater level. Machines with variable rotational speeds and excitation frequencies are particularly at risk.
Our solution: an elastic mounting system using steel springs and VISCO® dampers. Through targeted design, our engineers ensure rigid-body natural frequencies below 10 Hz and flexural natural frequencies of the foundation above critical ranges. This prevents natural frequencies from occurring within the operating frequency range—resulting in minimal resonance effects and reliable operation, even under changing conditions.
Implementation
Construction work began in March 2021, with commissioning taking place in August. Implementation was challenging because, in addition to limited space, the machine foundations had to be adapted to the high excitation forces.
The result:
- Effective vibration isolation: The transmission of vibrations was significantly reduced, both to the machine itself and to surrounding buildings.
- Improved manufacturing tolerances: The machine now produces with maximum precision without the machine operator having to constantly adjust settings.
- Sustainable solution: The flexible adjustment of spring stiffness makes the system future-proof and allows it to be adapted to changing operating conditions.
Share this post
Further Resources
You need further information on this topic?
Please do not hesitate to contact us with your individual question.
One of our project engineers will get back to you shortly.
Solutions for Block Making Machines
Solving neighbour complaints through effective vibration isolation in concrete block manufacturing
Concrete block machines are the heart of every concrete block factory. Their performance and precision significantly determine the quality of the concrete blocks produced. The high compaction forces generate strong vibrations that can affect not only the machines themselves but also surrounding buildings. Due to earlier foundation designs, elastomeric materials are almost exclusively used for vibration isolation in new designs for block making machines. This poses a considerable risk of resonance effects in the machine‘s operating frequency range.
Significant vibrations occurred in a newly constructed concrete block factory, which were even noticeable in the adjacent residential building. GERB was called in to develop a solution that would ensure trouble-free and long-term safe operation of the plant.
Solutions for Block Making Machines
Solving neighbour complaints through effective vibration isolation in concrete block manufacturing.
Concrete block making machines are the heart of every concrete block factory. Their performance and precision significantly determine the quality of the concrete blocks produced. The high compaction forces generate strong vibrations that can affect not only the machines themselves but also surrounding buildings. Due to earlier foundation designs, elastomeric materials are almost exclusively used for vibration isolation in new designs for block making machines. This poses a considerable risk of resonance effects in the machine‘s operating frequency range. Significant vibrations occurred in a newly constructed concrete block factory, which were even noticeable in the adjacent residential building. GERB was called in to develop a solution that would ensure troublefree and long-term safe operation of the plant.
Technical Challenge
The block manufacturing machine caused considerable vibrations in its operating frequencies between 25 Hz and 50 Hz. In this case, too, elastomer plates were originally chosen as the mounting solution, which led to the following problems:
- High vibrations affected manufacturing tolerances, leading to production deviations.
- Complaints from neighbours about clearly noticeable vibrations on glass false ceilings in residential buildings.
Limited space in the already completed plant made it difficult to implement a new storage solution.
Technical Challenge
The block manufacturing machine caused considerable vibrations in its operating frequencies between 25 Hz and 50 Hz. Elastomer plates were originally chosen as the mounting solution, which led to the following problems:
- High vibrations affected manufacturing tolerances, leading to production deviations.
- Complaints from neighbours about clearly noticeable vibrations on glass false ceilings in residential buildings.
Limited space in the already completed plant made it difficult to implement a new storage solution.
Solution
GERB developed a tailor-made concept to provide a sustainable solution to the vibration problem.
The use of steel springs in combination with VISCO® dampers has resulted in a significant reduction in vibrations. The bearing frequency was set to 3.3 Hz, although replaceable spring elements allow a further reduction to 2.5 Hz. In addition, a special construction method has reduced the surrounding air gap to just 100 mm.
GERB took over the planning from the initial feasibility studies to the implementation planning of the foundation block pit, the delivery of the elements, the assembly and the vibration measurements carried out after completion.
Did you know?
Structures that are supported directly on the subsoil or additionally mounted on a continuous elastic layer frequently exhibit resonance effects in the range of 10–50 Hz. Even with detailed geotechnical investigations, a large scatter in the dynamic soil parameters remains, further amplified by variations in soil moisture and groundwater level. Machines with variable rotational speeds and excitation frequencies are particularly at risk.
Our solution: an elastic mounting system using steel springs and VISCO® dampers. Through targeted design, our engineers ensure rigid-body natural frequencies below 10 Hz and flexural natural frequencies of the foundation above critical ranges. This prevents natural frequencies from occurring within the operating frequency range—resulting in minimal resonance effects and reliable operation, even under changing conditions.
Implementation
Construction work began in March 2021, with commissioning taking place in August. Implementation was challenging because, in addition to limited space, the machine foundations had to be adapted to the high excitation forces.
The result:
- Effective vibration isolation: The transmission of vibrations was significantly reduced, both to the machine itself and to surrounding buildings.
- Improved manufacturing tolerances: The machine now produces with maximum precision without the machine operator having to constantly adjust settings.
- Sustainable solution: The flexible adjustment of spring stiffness makes the system future-proof and allows it to be adapted to changing operating conditions.
Lorem ipsum dolor sit amet, consectetur adipiscing elit. Ut elit tellus, luctus nec ullamcorper mattis, pulvinar dapibus leo.
Solution
GERB developed a tailor-made concept to provide a sustainable solution to the vibration problem.
The use of steel springs in combination with VISCO® dampers has resulted in a significant reduction in vibrations. The bearing frequency was set to 3.3 Hz, although replaceable spring elements allow a further reduction to 2.5 Hz. In addition, a special construction method has reduced the surrounding air gap to just 100 mm. GERB took over the planning from the initial feasibility studies to the implementation planning of the foundation block pit, the delivery of the elements, the assembly and the vibration measurements carried out after completion.
Did you know?
Structures that are supported directly on the subsoil or additionally mounted on a continuous elastic layer frequently exhibit resonance effects in the range of 10–50 Hz. Even with detailed geotechnical investigations, a large scatter in the dynamic soil parameters remains, further amplified by variations in soil moisture and groundwater level. Machines with variable rotational speeds and excitation frequencies are particularly at risk.
Our solution: an elastic mounting system using steel springs and VISCO® dampers. Through targeted design, our engineers ensure rigid-body natural frequencies below 10 Hz and flexural natural frequencies of the foundation above critical ranges. This prevents natural frequencies from occurring within the operating frequency range—resulting in minimal resonance effects and reliable operation, even under changing conditions.
Implementation
Construction work began in March 2021, with commissioning taking place in August. Implementation was challenging because, in addition to limited space, the machine foundations had to be adapted to the high excitation forces.
The result:
- Effective vibration isolation: The transmission of vibrations was significantly reduced, both to the machine itself and to surrounding buildings.
- Improved manufacturing tolerances: The machine now produces with maximum precision without the machine operator having to constantly adjust settings.
- Sustainable solution: The flexible adjustment of spring stiffness makes the system future-proof and allows it to be adapted to changing operating conditions.
Share this post
Share this post
Further Resources
You need further information on this topic?
Please do not hesitate to contact us with your individual question.
One of our project engineers will get back to you shortly.
Further Resources
You need further information on this topic?
Please do not hesitate to contact us with your individual question.
One of our project engineers will get back to you shortly.