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PROCESS DESCRIPTION

HOLLOWCORESLABPRODUCTIONBYEXTRUDER


HOLLOWCORESLABPRODUCTIONPLANT



HollowcoreslabproductionbyExtruder
D000055373/EN/B
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Keywords:Hollowcoreslabproductionplant,prestressedhollowcoreslabs,extruder,precastflooring,flooring

PROCESSDESCRIPTION
HOLLOWCORESLABPRODUCTIONBYEXTRUDER




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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



PROCESSDESCRIPTION
HOLLOWCORESLABPRODUCTIONBYEXTRUDER




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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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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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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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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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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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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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2.10. Handlingoftheslabsinstorage
Anoverheadcraneequippedwithliftingclampsisusedforhandling
theslabsinthestorageandloadingtheme.g.ontrucksfordispatch
tothebuildingsites.

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



www.elematic.com

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