TABLE OF CONTENTS - The Professional Green Building Council

Theme C: Education and Market TransformationInternal transportation within the plant, either indoors or outdoors, and between thequarry and the plant is also included as a sub-process. In the distribution phase,blocks are either provided directly to the end customers/construction site in orderto shorten the distance or to the subsidiary sellers.An important item for the manufacturing process is the maintenance and repair ofmachinery and moulds. Factories are usually closed for about 1-3 weeks in a yearin order to have a proper maintenance.3.3.1. Manufacturing of pumice concrete blocksThe processes of pumice concrete block production in the investigated factory aremainly: (i) mixing, (iii) moulding, (iv) drying, (v) packaging, (vi) storing, and (vii)distribution. Sometimes an additional crushing process prior to mixing processtakes place when pumice aggregates are stored in the production bunker without asorting process.In the mixing process, pumice aggregate transported by a conveyor and anelevator, cement supplied from the silo located at the top of facility and watersupplied by pipeline system are mixed in an automatic-controlled mixer. Sensors inthe mixer measure humidity and required water is added to the mixerautomatically. Iron-oxide used for colouring is manually added to pumiceaggregate while being transported on conveyor.In the moulding process, pumice concrete paste coming from the mixer is injectedand pressed into steel mould and placed by vibration. Following this shapingprocess, wet blocks are burred and transported to drying chamber by automaticcontrolled transport tower. Moulds have to be replaced twice in three months. Theyare made in the metal atelier of the factory.In the drying process, wet blocks remain in the drying chamber for 72 hours. In thesummer period, wet blocks dry naturally. In the winter period, air temperature inthe chamber is preserved at a minimum of 15 0 C by heating. Following the drying647