Fully Automatic Production Methods of Precast Concrete Wall Panel
The company uses the architectural perspective drawing from customers to design the precast concrete walls, and at the same time analyze the structural engineering. By using the real 3D system software, it helps us to see the products in actual dimension. Moreover, we can add the conduits, joints, steel, and automatic joints according to the customers’ needs using real 3D system. After the design is approved, our company will commence with the aim of highest customers’ satisfaction, so the customers can be assured that their products will be delivered on time. The fully automated precast concrete wall manufacturing methods are as follow:
Cleaning and Oiling – The pallet cleaner cleans the surfaces of the pallet from any traces of concrete sticking on it. The pallet oiler ensures that the shuttering pallet is automatically sprayed with formwork oil. Shuttering cleaners and oilers clean and oil the shuttering so that it can be brought back automatically into a new cycle.
Plotting – The plotter has the task of marking the layout of the shuttering and the inbuilt parts on the shuttering pallet.
Shuttering – The precast wall are shuttered according to the design with automatic shuttering robot, which has the same quality as car manufacturing robot. The walls will have the exact dimension as the design with highest degree of precision of minus or plus 2 millimeters and can be assembled easily with higher quality on site.
Reinforcement – The machine will lift the steel for reinforcement, which are manufactured under the computerized control system, and load it onto the pallet, where the technician will approve the correctness before pouring the concrete. During the reinforcement process, we use the fully automated machine to weld the reinforce steel to match with the actual structure load requirement, so the customers can be assured of the precast concrete wall quality. At the same time, we can also add conduits and pipe according our customers’ approved design, which later, will reduce the construction time and increase the construction yield.
Casting – The casting will be completed on the pallet as computer generated.
Compacting – With proper compacting frequency, we can reduce the cost of plastering the surface of the element on site, and at the same time strengthen the precast concrete walls due to less gap or bubble in the concrete. Then, the surface is smoothened and polished with the smoothening device. These processes all together make it easier to paint or to attach the wallpaper later on the construction site.
Curing – Curing will enhance the strength of the concrete and reduce the plastic shrinkage on the surface. This makes the surface of the concrete look smoother. The temperature in the curing chamber is controlled at 60 ºC – 70ºC, with 75% humidity and our chamber can hold up to 108 panels per one cycle.
Stripping – The mold and shutter will be removed, and the cured concrete is ready for the next process
Demoulding – The wall are demoulded from the pallet to store in the stockyard. They are planned by the computer with the backward planning method. The walls that will be delivered and stored together, so the customer can be assured that the wall will be delivered according to their construction plan.
Product Removal – The product will be moved out of the building to the stockyard, which can be delivered promptly to the customers.