PROCESS DESCRIPTION HOLLOWCORESLABPRODUCTIONBYEXTRUDER

D000055373/EN/B 1(13)

HOLLOWCORESLABPRODUCTIONPLANT

HollowcoreslabproductionbyExtruder

Keywords:Hollowcoreslabproductionplant,prestressedhollowcoreslabs,extruder,precastflooring,flooring

PROCESSDESCRIPTION HOLLOWCORESLABPRODUCTIONBYEXTRUDER

D000055373/EN/B 2(13)

Content

page

1. Introduction ............................................................................................................................ 3 1.1. Advantages ................................................................................................................... 3 2. Production process ................................................................................................................ 5 2.1. Cleaning of beds and pulling of strands ........................................................................ 6 2.2. Tensioning of strands .................................................................................................... 6 2.3. Concrete transportation................................................................................................. 6 2.4. Extruding ....................................................................................................................... 7 2.5. Draw openings by plotter .............................................................................................. 7 2.6. Making of openings (if needed), covering the slab ........................................................ 7 2.7. Cutting on the bed ......................................................................................................... 8 2.8. Lifting of the slab, drilling of drainage holes .................................................................. 8 2.9. Transportation to storage .............................................................................................. 8 2.10.Handling of the slabs in storage .................................................................................... 9 3. Production facility requirements .......................................................................................... 10 4. Technical data ..................................................................................................................... 11 5. Additional information .......................................................................................................... 12

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PROCESSDESCRIPTION HOLLOWCORESLABPRODUCTIONBYEXTRUDER

D000055373/EN/B 3(13)

1. Introduction

1.1. Advantages Prestressedhollowcoreslabsareamongthemostadvancedproductsintheprecastconcreteindustry, especiallywithregardtotheirhighqualityandlowconsumptionofmaterials. Hollowcoreslabsarethemostwidelyusedtypeofprecastflooring.Thisisduetothehighlyefficient designandproductionmethods,choiceofunitdepthandcapacity,smoothundersideandstructural efficiency. Hollowcoreslabshavelongitudinalcores,whosemainpurposeistoreducetheweightofthefloor.They aremainlyusedinbuildingswithlargespanssuchasofficebuildings,hospitals,schools,shoppingcenters, industrialbuildings,etc.Anothercommonapplicationisapartmentbuildingsandhousesbecauseofthe favorablecostrateandthefasterection. Generally,prestressedhollowcoreunitshavenoreinforcementotherthanthelongitudinalprestressing strandsatthebottom.Hollowcoreslabsdonothaveorneedanytransversalreinforcement.Upperstrands areusedincantileverslabsolutionsoragainstloadscausedbyhandling. Prestressedhollowcoreslabsarenormally1200mmwideandupto20mlong.Standardslabheightsvary between150to500mm.

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PROCESSDESCRIPTION HOLLOWCORESLABPRODUCTIONBYEXTRUDER

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Prestressedhollowcoreunitsaremanufacturedusingeitherlonglineextrusionorslipformprocesses.The steelbedsareusually1200mmwideand80to150mlong. Thedegreeofprestressing,strandpatternanddepthofunitsarethemaindesignparameters. TheElematicmanufacturingprocessdeploysdrymixconcrete,whichmeanslesscementisneeded comparedtoconventionalprocesses. Thevoidssaveroughly50%concretecomparedtomassiveslabwithsamethickness;thatis27.500tonsa year(whenproductionis100.000m,200mmdeepslabs). Theprestressingprocessreducestheconsumptionofsteel.Thenspansareover3.5msavingcanbe50%or evenmore.Thatmeansseveralthousandsoftonsina100.000m/acapacityfactory.Benefitsaremore substantialwhencomparedwithreinforcedconcreteslabproduction. WiththeproductionprocessusingmodernstateoftheartElematicmachinesandexperiencedcrews,you canachievesavingsof2530%inlaborhourscomparedwithconventionalslabproduction.Youcan manufacture1.5to2.5mhollowcoreslabswithsamematerial,energyandlaborcostsyouneedto produce1mslabswithequivalentdepth.

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PROCESSDESCRIPTION HOLLOWCORESLABPRODUCTIONBYEXTRUDER

D000055373/EN/B 5(13)

2. Productionprocess

1. Cleaningandoilingofthebed 2. Strandpulling 3. Tensioningofstrands 4. Liftingtheextruderonthebed(not shown) 5. Concretemixing(notshown) 6. Concretetransportation 7. Concretedosingtoextruder(notshown 8. Extruding 9. Drawopeningsbyplotter(notshown) 10. Makingopenings 11. Coveringofslab 12. Curingofslab 13. Recoveringofslab 14. Cuttingofslab 15. Liftingofslab 16. Drillingofdrainageholes 17. Transportationtostorage 18. Handlingofslabsinstorage 19. Transportationtosite

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PROCESSDESCRIPTION HOLLOWCORESLABPRODUCTIONBYEXTRUDER

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2.1. Cleaningofbedsandpullingofstrands Prestressedhollowcoreslabsareproducedoncastingbeds.Before casting,thebedsarecleanedandoiled.Thenthestrandsarepulled andspreadbyaspecialdevice,BedMaster,whichsimultaneously cleansthepalletwitharotatingbrush.WhentheBedMasterreturns totheactiveend,itliftsthestrandsonthecastingbedandoilsthe bedwithformoil. BedMasterEL411 2.2. Tensioningofstrands Allofthestrandsforonebedaretensionedsimultaneously(or singlestrandscanbeindividuallytensioned).Aspecialunithasbeen developedforthispurpose.Theunitmovestransverselyatoneend ofthehallsothateachcastingbedcanbehandledbythesame machine. Castingbedspecificstressingcylinderscanbeusedasalternative stressingmethod. Prestressingdevice 2.3. Concretetransportation Concreteistransportedfromthebatchingandmixingplantbyan overheadtransportsystem.Ashuttlebringstheconcretebatch automaticallytocorrectplaceoveranoverheadbucketgantry, whichdischargesthebatchintotheextruder.

Shuttleandextruder

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PROCESSDESCRIPTION HOLLOWCORESLABPRODUCTIONBYEXTRUDER

D000055373/EN/B 7(13)

2.4.

Extruding Ahighperformanceextruderisthekeycomponentinthe productionprocess.Itextrudestheslabsascontinuousprocess.

ExtruderE9 2.5. Drawopeningsbyplotter Allopeningstobemadeinslabsaremarkedwiththeplotter.Also thepointwheretheslabiscutorsplit,recessesandneededslab identificationdataaremarkedwiththeplotter.Slabdataneededfor plottingisloadedintheplotterinadvance.

Plotter

2.6. Makingofopenings(ifneeded),coveringtheslab Recessescaneasilybemadeafterthecastingprocesswhilstthe concreteisstillgreen.Openingscanbemadewithamachineofby hand.Whentheprocesshasbeencompleted,thecastslablineis coveredwithtarpaulinstominimizeevaporation. Openingsinthefreshlycast slab

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PROCESSDESCRIPTION HOLLOWCORESLABPRODUCTIONBYEXTRUDER

D000055373/EN/B 8(13)

2.7. Cuttingonthebed Aftercuring,tensionofthestrandsisreleasedandtheslabiscut accordingtomeasuredmarkings.Cuttingoperationiscarriedout withdiamondtippedsawthattravelsonthesamerailsasthe extruder. SlabsawEL1300A

2.8. Liftingoftheslab,drillingofdrainageholes Afterthecutting,slabsareliftedfromthecastingbedbyan overheadcranewithclamps.Theslabsarethentransferredtoan automaticdrillingdevicethatdrillsdrainageholesinbothendsof theslab.

Liftingbeam

2.9. Transportationtostorage Slabswhicharesetontransferwagonsnowundergoqualitycontrol, afterwhichthevoidsarefittedwithsealingplugsandtheslabends markedwithprojectnumbers,etc.Thenthewagonsproceedtothe storage.

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PROCESSDESCRIPTION HOLLOWCORESLABPRODUCTIONBYEXTRUDER

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2.10. Handlingoftheslabsinstorage Anoverheadcraneequippedwithliftingclampsisusedforhandling theslabsinthestorageandloadingtheme.g.ontrucksfordispatch tothebuildingsites.

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PROCESSDESCRIPTION HOLLOWCORESLABPRODUCTIONBYEXTRUDER

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3. Productionfacilityrequirements
Theproductionhallislikeanormalindustrialhall.Thehallhastofulfillthelocalrequirementsandits structuresneedtocarryverticalloadsandbendingmomentofnormalloadsandloadsfromfactory equipmentlikecranes,shuttles,tracks,etc.Lengthoftheproductionhallisabout20m+bedlength+30 m.Foroptimalcasting,theambienttemperatureshouldbearound+20C. Electricity:Normallytheplantgetsitspowerfromthelocalelectriccompany,butsometimesaplantsown generatorisusedforheatingofconcrete,castingbedsandproductionhallandotherfacilitieslikeusage water,office,etc.Theneededheatingpowerforaplantwith4castingbedsisapprox.450kWand700kW foraplantwith8beds. Watercomesusuallyformalocalwatersupplier.Watercanbedividedtosocalldrinkingwaterand processwater(notdrinkable).Processwaterisusedformachinerycleaningetc. Wastewatertreatmentplantisnowquitecommon.Recycledwaterisreusedformachinerycleaning, washing,etc. Wasteconcreteandrejectedslabsarenormallystoredinastorageareaandwhenapileishighenough, thewasteconcreteiscrushedintosmallerpieces.Thiscrushedproductcannotbenormallyusedfor hollowcoreslabproductionbutitcanbeusedforfillingpurposes.Steelisseparatedduringthecrushing andsuppliedtosteelmillsforrecycling. Storageareaisnormallyanopenarealocatedattheendoftheproductionhall.Therearegantrycranes, overheadbridgeorAframeloadingsystems.Thecranesliftsingleslabsorbundleofslabsonto15mof slabsrequire1mgroundarea,drivewaysfortruckandoutdoortransportationwagonstakealsotheir shareofthegroundarea. Arackforslabtesting,i.e.forcarryingout1:1fullscalestrengthandbendingtests,canbelocatedinthe storagearea.Alsoanareaforrecuttingtheslabs,whichareusablebutneedsomeadditionalwork(a shorteningorananglecutetc.)isneeded.

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PROCESSDESCRIPTION HOLLOWCORESLABPRODUCTIONBYEXTRUDER

D000055373/EN/B 11(13)

4. Technicaldata
Constructionofaproductionplantnormallystartsbymakingthefeasibilitystudytakingintoaccountthe market,needs,constructioncircumstances,buildingtypes,financingetc.requirements. Theproductioncapacityofafloorproductionplantiscalculatedbasedonannualcapacity. Thesmallestproductionplantcontainsjustonesinglecastingbed,butitisnotveryeconomical.Biggest plantscanhaveseveralproductionhallswhileonehallmayhave812castingbeds. Designdrawingofahollowcoreslabproductionhall

Annualcapacity(example) Requiredannualproductioncapacityis200.000mwithonecastingbedperdayandwith250working days. Thecalculateddailycapacityis200.000m/250d=800m/d.Thisgives800m/1.2m=666.7linealmeters ofslab. 6linesofbeds111.1m+6m117m with6x6mx1.2m=43.2mofwasteor 5linesofbeds133.3m+6m139m with5x6mx1.2m=36mofwaste. Wechoose5castinglineseach144long. Thisgivesanannualcapacityof5x(1446)x1.2x250=207.000mcastonceaday,andiftwofull8h shiftsareused,itispossibletocast23bedstwiceadayandincreasethecapacity. Somecastingbedscanbecasttwiceaday(dependingonthecementquality(hardeningtime),process cycletimeandworkingtimes).Asaverage,iftheproductioncapacitymustbeincreasedwithexistingbed capacity,thecapacitycanbecalculatedsothatthedailycastingfactoris1.21.5,butthecycleanddaily

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PROCESSDESCRIPTION HOLLOWCORESLABPRODUCTIONBYEXTRUDER

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workingtimemustbechecked.Alsotheplanttypedetermineshowthecastingispossible,i.e.whentwo castingmachinescancastparallel,itiseasiertocastsomebedstwicecomparedtoonecastingatatime. Theproducttype(thicknessoftheslab)alsoaffectsthecastingcycleandtimes,smaller(i.e.thinner) productscanbecastfasterthanthickerones.Alsootherthingslikequantityofopening,recessesetc.will affectthecastingtime. Workscheduleforfourbedhallwithonecastingmachinewherecastingisdoneonceaday.

5. Additionalinformation

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PROCESSDESCRIPTION HOLLOWCORESLABPRODUCTIONBYEXTRUDER

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Elematicisaleadingsupplierofprecastconcretemachineryandequipmentaswellastheonly suppliercapableofdeliveringcompleteproductionplantsanywhereintheworld.Elematics superiortechnologyandindustryexpertiseiscurrentlyinuseinmorethan100countriesacross fivecontinents.ElematicisheadquarteredinToijala(Akaa),Finland.

www.elematic.com

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