3.

0 PRODUCTION PLANNING
Prefabrication is the practice of assembling the components of a structure in a factory
or other manufacturing locations, and then transporting complete assemblies or sub-
assemblies to the construction site where the structure is to be erected. Whereas,
traditional building construction takes place on site, prefabrication has gained much
interest in recent years, particularly with regard to industrial buildings, for its potential
energy saving benefits, as well as improved efficiencies in the construction process.
Consequently, the efficiencies gained in the production process of precast components
directly enhance the construction time and cost of buildings. (Robert, 2018).
Generally, these methods involve various stages, including precast component
design, material management or transshipment, precast component production
planning, precast component inventory control, precast component transportation and
site assembly. It is well established that production planning is the key element in the
precast production process and it is closely related to the production time and cost.
Planning involves the allocation of resources over a period of time to perform a series
of jobs that are subject to known constrains. (Nordimpianti, 2019).
i. Design and Planning
With the drawing and construction of a floor plan inside a structure, the hollow core
manufacturing process starts. The use of the building and loads applied will decide the
width, prestressed wire patterns and span of the slabs.
Using 3D CAD tools, the design is achieved. For the hollow core plant, this will then
be converted into a production plan. Any extra material is included, such as the
insertion of lifting pins, cut-outs and narrow modules. Production is carried out by a
team of factory workers, and is frequently distributed over several shifts of operation.
Planning for production is an important aspect of optimizing productivity and
minimizing raw material waste. (Jake Bill, 2019).
 Figure 3.1 AutoCAD tools
(Source:https://all3dp.com/2/best-autocad-alternatives/)

ii. Preparation of Casting Beds

Hollow core slabs are cast onto steel pallets or beds that are typically upwards of
100m in length. Prior to casting, there are a number of operations required in order to
prepare them. They must be cleaned of any debris from previous casting cycles and
sprayed with an oil release agent. This is typically carried out by a multi-purpose
machine or bed cleaner. The prestressing tendons must then be run down the length of
the bed in preparation for tensioning. (Alfrendo Satyanaga, 2016).

Figure 3.2 Casting beds

(Source:https://weckenmann.com/en/products/formwork/stationary-casting-bed-and-
production-table)
iii. Prestressing
Hollow core slabs are prestressed concrete elements. This means that they are
reinforced by high strength, low relaxation steel wire or strand. Prior to casting the
slabs, the tendons are stressed to a predetermined load. Prestressing helps the hollow
core slabs to overcome the inherent stiffness of concrete under friction, allowing
longer spans between bearing points. In the phase, the connection between the
concrete and the prestressed tendons is essential. (Lee, Y.-J., Dong Hwan Kim, 2020).

Figure 3.3 Prestressing

(Source:https://www.mdpi.com/2076-3417/10/5/1636)

iv. Concrete Batching and Distribution

The concrete mix required to manufacture hollow core slabs varies depending on the
casting machine used. Planetary or twin-shaft mixers are typically used. High quality
materials are desirable, and may be supplemented with additive (admix) chemicals.
Once batched and mixed, the concrete may be delivered to the casting machine via a
concrete skip using mobile plant, overhead or semi-portal cranes. (Skako, 2014).
 Figure 3.4 Concrete batching plant
(Source:https://www.bft-international.com/en/artikel/
bft_Conflex_Higher_distribution_speed_greater_plant_productivity_2067007.html)

v. Casting
Once the concrete has been delivered to the casting machine, it begins to form the
hollow core slab. There are 3 main types on casting machine: Firstly, it is extruder.
Casts the slab using a dry mix with low cement content, and compacts the concrete
with high frequency vibration. The build up of concrete and auger drive moves the
extruder down the casting bed. Secondly, it is slipformer. Casts the slab in 2 or 3
stages, using a drive mechanism and vibration to form the slab around moving steel
cores. They also have the flexibility to cast other elements that have a continuous
profile. And lastly, it is flowformer. Casts the concrete without mechanisms or drive
units. The concrete flows by gravity and vibration. The process uses plastic quality
concrete for versatility of cross section profile options with a smooth, rough or
indented surface finish. (David Citek, 2017).
 Figure 3.5 Casting
(Source:https://www.nordimpianti.com/Products/Casting-Machines/Wet-Casting-
Series-WF/Wet-Casting-for-Hollow-Core-Slabs)

vi. Detailing
Hollow core slabs often require additional detailing, such as openings, shelf-angles,
narrow widths, and insertion of lifting pins. Some factories may use an automated
Plotter, which is linked to the design or planning software – to accurately mark out
these details and record data. Vacuum suction machines or aspirators can be used to
remove concrete and create openings. Wet cut saws are used to make longitudinal or
‘rip cuts’ in the fresh concrete. (J.B Mander, 2006).

Figure 3.6 Detailing of Hollow Core Slab

(Source:https://hollowcore.org/hollowcore/production/)
vii. Curing
When a cloche arrives in the curing hall, the full length and width of the bed is
immediately lowered to the bed to protect the product. A series of tubes with outlet
nozzles are mounted under the cloche along the entire length, the purpose of which is
to spread steam and contain it over the product to speed up the curing process. Once
cast, insulated covers are normally used to assist with curing of the slabs, and to retain
moisture. Additional water or steam heating under the casting beds may speed this
process up further. (Nordimpianti, 2019).

Figure 3.7 Curing of hollow core slab

(Source:http://www.indiaprecast.com/long-line-bed/curing-station.html)
viii. Detensioning
It is safe practice to progressively relieve the tension before cutting the element to size
until the concrete has achieved the necessary strength to overcome the retracting force
of the internal prestressing wires. If the stress was to be unexpectedly removed when
cutting while the whole aspect was still under tension along the bed, this minimizes
the chance of concrete cracking.Once the appropriate strength has been reached, the
concrete will have bonded effectively with the prestressed tendons. They can then be
detensioned, capturing the prestressing load within the slab. The detensioning
cylinders are mounted in the reaction beams (detensioning side) in the single wire
stressing wire which are used to relieve the strain of the steel wires until the
prestressed concrete part is cut. They are extensively plated with chromium. High
pressure tubing and fast release connections attach the detension pump assembly to
the cylinders. (Nordimpianti, 2019).

Figure 3.8 Detensioning of hollow core slab

(Source:https://www.nordimpianti.com/Products/Stressing-and-Detensioning/
Detensioning-System)
ix. Cutting
The bed comes to the cutting station and, at this point, the 150 meter long linear
segment of concrete is cut into individual product lengths. The cutting machine is
fitted with diamond edge cutting blades which during operations are cooled with
water jets. Saws are used to cut slabs to the correct length, and at different angles.
Water is used to dampen the blade and reduce dust. Additional cutting stations can
sometimes be utilized outside of the factory. A drag chain system conveys the cement
slurry produced by the water-cooled cutting process to the recycling plant below
level. After the cutting process is finished, the bed is pushed horizontally to the
stripping line. (Paseo de los, 2014).

Figure 3.9 Cutting of Hollow Core slab

(Source:https://www.okorder.com/p/prestressed-concrete-hollow-core-slab-cutting-
machine_951215.html)
x. Stripping of Beds
Slabs are removed from the casting bed using clamps and lifting beams, in
conjunction with cranes. Slabs also are lifted from the casting bed after the cutting by
an overheard crane with clamps. The slabs are then moved to an automated drilling
system on both ends of the slab that drills drainage holes. (June R., 2016).

Figure 3.10 Stripping of Beds of Hollow Core Slab

(Source:https://www.precastmachinery.com/stripping-machines-for-hollow-core-
slabs/)

xi. Storage
Slabs may be removed from the factory on bogeys, using forklift trucks, or side
loaders. They are stacked on timber bearers in the stockyard. Slabs placed on transfer
wagons are now subject to quality control, after which the voids are fitted with sealing
plugs and project numbers are labeled on the slab ends, etc. The wagons then move to
storage. For handling the slabs in the storage and assembling them, such as on trucks
for dispatch to the construction sites, an overhead crane fitted with lifting clamps is
used. (Yaoshi, 2013).
 Figure 3.11 Storage of Hollow Core Slab
(Source:https://www.constructioncanada.net/elevating-utility-of-buildings-with-
hollow-core-precast-concrete-slabs/2/)

xii. Delivery and Installation

Traceability from design and production planning software is carried through to the
stockyard, so that individual slabs can be identified. They are loaded onto trailers and
delivered to site, where they can be installed using lifting clamps with spreader beams
or chains. In compliance with the drawing of expocrete, hollow core slabs are to be
located and installed. Minimum end bearing is 75mm as stated otherwise on drawings.
Then, preserve standardized slab joint widths. Every core should be tapped at the end
to provide drainage if there is a risk of trapping water in the cores. (IPHA, 2019).

Figure 3.12 Delivery and installation of hollow core

(Source:https://hollowcore.org/hollowcore/production/)
Site Layout
Using a multi-stage model, site development designs can be optimized to prevent
needless changes to facility settings through construction phases, improving
performance. In each construction process, excessive installation relocation can be
required without adequate preparation, resulting in higher construction costs and
longer construction time due to the need to uninstall and set up site facilities. The
mathematical objective function set out in the solution process attempts to reduce the
overall cost, consisting of the cost of material transfer between the related site
facilities and the cost of removing, installing and relocating all the site facilities
involved in each step of development. (Johnny Paul, 2017).

Figure 3.12 Site layout of Hollow Core Production

Conventional layouts consist of batching and mixing plant concrete, then conveying it
to several parallel casting beds with prestressing abutments at the ends of the casting
lines. There are also improved layouts, some of them have moving mould (casting
beds) or stationary sawing stations. The target is to increase productivity and improve
the safety and working environment. The basic workflow in factories is preparing
casting beds, pulling and attaching prestressing wires or strands, prestressing, forming
slab around the reinforcement, marking and identifying slabs, making openings,
curing long slabs, cutting slabs to delivery lengths, drilling drainage holes and lifting
slabs to stockyard stacks.
REERENCE
1. Robert, (2018), D000023370, Eng, & Eng. PROCESS DESCRIPTION HOLLOW-
CORE SLAB PRODUCTION BY EXTRUDER HOLLOW-CORE SLAB
PRODUCTION PLANT HOLLOW-CORE SLAB PRODUCTION BY EXTRUDER.
Retrieved from
https://www.ceeind.com/public/data/companyCatalogue1233069526.pdf
2. Nordimpianti, (2019), Machinery and Equipment Products Technology for the
Precast and Prestressed Concrete Industry. Retrieved from
https://www.nordimpianti.com/brochures/eng/pdf_mr/2.0_ENG_Products.pdf
3. Jake Bill, Production - IPHA - International Prestressed Hollowcore Association.
(2019, June 20). from IPHA - International Prestressed Hollowcore Association
website: https://hollowcore.org/hollowcore/production/
4. Satyanaga, A. (2016). AD01CTS - ADVANCED CONSTRUCTION
TECHNOLOGY AND SERVICES. Retrieved from
http://www.trentglobal.edu.sg/wp-content/uploads/2016/09/Lecture3-Precast-
Concrete27Dec16notes.pdf
5. Lee, Y.-J., Kim, H.-G., Kim, M.-J., Kim, D.-H., & Kim, K.-H. (2020). Shear
Performance for Prestressed Concrete Hollow Core Slabs. Applied Sciences, 10(5),
1636. https://doi.org/10.3390/app10051636
6. Skako, Concrete Plant Precast Technology. (2014). Retrieved from Bft-
international.com website:
https://www.bft-international.com/en/artikel/bft_Conflex_Higher_distribution_speed_
greater_plant_productivity_2067007.html
7. David Citek, IOP Publishing. (2017, September). Figure 4. Model of a hollow core
slab. If a thin slab is cast in... Retrieved from ResearchGate website:
https://www.researchgate.net/figure/Model-of-a-hollow-core-slab-If-a-thin-slab-is-
cast-in-horizontal-position-most-of-the_fig4_319867996
8. J.B Mander, (2006, June). Figure 1: Hollow-core connection details used by
Matthews [6], Lindsay... Retrieved from ResearchGate website:
https://www.researchgate.net/figure/Hollow-core-connection-details-used-by-
Matthews-6-Lindsay-7-and-MacPherson-8_fig1_45676415
9. Nordimpianti, WORLDWIDE A new approach to the production of hollow core
prestressed precast flooring. (2019). Retrieved from
https://www.nordimpianti.com/imm_utente/003_BISON_UK_ENG_p11_151075867.
pdf
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Retrieved , from Nordimpianti.com website:
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System‌
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hollow-core-slabs/
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HOLLOW-CORE SLAB PRODUCTION BY EXTRUDER HOLLOW-CORE SLAB
PRODUCTION PLANT HOLLOW-CORE SLAB PRODUCTION BY EXTRUDER.
Retrieved from
https://www.ceeind.com/public/data/companyCatalogue1233069526.pdf
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(2017, April 13). Retrieved January 7, 2021, from Construction Canada website:
https://www.constructioncanada.net/elevating-utility-of-buildings-with-hollow-core-
precast-concrete-slabs/2/
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June 20). Retrieved January 7, 2021, from IPHA - International Prestressed
Hollowcore Association website: https://hollowcore.org/hollowcore/production/
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INDIAPRECAST. (2017). Retrieved January 7, 2021, from Indiaprecast.com website:
http://www.indiaprecast.com/hollow-core-slab/plant-layout-list-of-machine.html