WHAT MAKES AN EFFICIENT PRECAST WALL PRODUCTION LINE?

Elematic
is well-known globally for hollow core technology but the company also has a
strong product line for precast wall element production, with three ready
layout concepts – the SEMI, PRO and EDGE – depending on the amount of
automation and production capacity needed.

But
there are many other solutions available. “We have a wide range of other layout
options for different capacities which have been proven to perform well in many
existing factories.  Our strength lies in our customized wall production
solutions.” commented Toni Koitmaa, Product Director, Wall Technologies,
Elematic, based in Finland.

A
full range of wall manufacturing equipment

One
device that seems to be making a huge difference in improving the efficiency of
wall production lines is the central transfer wagon, especially when the
product range includes both simple, fast moving elements and complex panels
that require more production time. “The central wagon moves the elements that
take more time to be fabricated away from the main line so bottlenecks in
production are avoided. This allows the elements that are fabricated faster to
move forward and makes production very flexible,” Koitmaa points out.

Pre-defined
processes and proper documentation during the whole manufacturing process are
important to ensure consistency in production and quality control. “Table
moulds, for example, are a long-term investment. You have to ensure that the
moulds can support the requirements set for the wall element. Table moulds have
to be flat and straight and must withstand the load placed on them without
bending. It takes a lot of expertise to make mould tables within strict
tolerances,” Koitmaa says.

The
casting machine is another crucial piece of equipment. Elematic’s Comcaster is,
in Koitmaa’s words, “very unique, very accurate and fast,” while allowing for
lower water-cement ratio. It can also cast stiffer grades of concrete than
conventional casting machines and reduces surface finishing time.

Decreasing
waste in the precast production process and improving cost-efficiency and
safety are goals to keep in mind. “You can use half the usual amount of wood
needed for table moulds, battery moulds and column- and pillar production by
using the right shutter system. The FaMe system is comprised of push button
magnets and aluminium side forms to replace wood and steel, which leads to
substantial savings.” Koitmaa adds that the FaMe system was designed to improve
work safety and lower the chances of finger injuries.

Battery
moulds, which are used to cast solid load-bearing walls, can likewise have a
big effect on efficiency.  The cold shutter system, which is offered by
very few equipment manufacturers in the industry, practically doubles the
capacity of a standard battery mould. By transferring the cold shutter plates
to the battery mould after the previously cast elements has been taken out, the
casting cycle is significantly accelerated. “The cold shutter system really
speeds up the production cycle since only casting and hardening take place
inside the battery mould. Using it is a great way to increase capacity,”
Koitmaa explains.

Digitalisation
also goes a long way towards reaching peak efficiency. “Using digital systems
can help you get the maximum capacity from precast lines by optimising the
process at different stages of production, leading to faster delivery time and
saving on resources,” Koitmaa said. At this year’s BAUMA, Elematic launched the
WallMES, as part of the digital Plant Control solution for precast plants.

Tried
and tested on factory floors

Some
examples of Elematic circulation lines in operation:

An
Elematic production line is helping change the cityscape in the Nizhny Novgorod
region in Russia. Karkas Monolit’s line has a capacity of 280 000 m²
per year, with 40 tables, three concrete transportation shuttles, a transfer
wagon, a compaction station, a tilting station and a transport wagon. Their
factory is the biggest in the region.

Norway’s
Block Berge Bygg AS, whose production accounts for about 15 percent of the
total concrete element market in Norway, has adopted an Elematic circulation
line with an output 1500 m² per week.

Finnish
Santalan Betoni has also invested in Elematic’s circulation line for their new
precast wall factory. The line includes, among others, 26 tables, a Comcaster
E9 casting machine, tilting tables and two transfer wagons. 

The
Elematic Wall Production Lines

SEMI,
for precast wall production between 70,000 to 150,000 m² per year.
SEMI Wall features straightforward and easy-to-learn basic technology.

Theoretical
capacity:          280-600 m²
/ day (one casting)

Personnel:                         
10

Production
area:                
2000 m²

Land
area:                         
20000 m²

No. of
tables:                     
10-15

Typical
table
size:              
3.5 x 8.0 m

PRO,
for precast production in the annual range of 170,000–300,000 m².
All the PRO key functions are automated. The PRO Wall line consists of a circulation
line and optional battery molds and tilting tables.

Theoretical
capacity:          680–1200 m²
/ day (one casting)

Personnel:                         
12–20

Production
area:                
2800 m²

Land
area:                         
45000 m²

No. of
tables:                     
20–30

Typical
table
size:              
3.8 x 9.0 m

EDGE,
for very high capacity – in the annual range of 400,000–750,000 m² –
with a wide product range and highly automated precast production. The tables
move automatically between the production steps for high productivity.
Logistics are enhanced with a central transfer wagon that ensures smooth
traffic. Productivity is further improved by a fully automated concrete
transportation and an automatic shuttering station.

Theoretical
capacity:          1600–3024 m²
/ day (one casting)

Personnel:                         
30–35

Production
area:                
9000 m²

Land
area:                         
70000 m²

No. of
tables:                     
40–60

Typical
table
size:              
4.0 x 10 m

For
more information, please contact:

Nina
Lehtonen

Marketing
Manager, Elematic Oyj

[email protected]

Issued
by: SJC Creative, Sue Charlton, Tel: 087 701 3860 Cell: 082 579 4263

Email: [email protected]