Prefabricated panels

Prefabricated Panels

INDEX

Precast concrete panels have been extensively used in the past. Currently, these panels can be used and have been employed in the construction of a variety of structures such as offices, warehouses, apartments, recreation centers, markets, churches and all types of industrial and commercial buildings.

The panels can be manufactured in many different shapes and sizes, although most manufacturers have a standard panel.

All these panels are usually designed to meet the needs of a particular work and have advantages over other materials of possible use.

The panels offer greater thermal insulation than traditional elements, resulting in lower energy consumption for heating or cooling of buildings. Something similar can be said about fire safety and savings obtained insurance in the event.

The use of pre cast panels offers other advantages, which may include eliminating the need for perimeter columns and horizontal greater resistance to impacts of horizontal loads, which are possible in industrial establishments.

The pre-cast concrete panels are more resistant to penetration of air and moisture, allowing storage of the walls without danger of deterioration, often used in car washes where the panels are permanently wet with no signs of deterioration.

The pre-cast concrete panels can be fabricated and raised, to a height of 15 m, which is an important factor in some buildings.

These pre-cast panels can be manufactured with a very large variation in both surface texture and color. The interior smoothness are finished can, with minimal preparation, paint or cover with paper or other coatings.

Structures using pre cast concrete panels can be built in 75% of time spent on the case of using conventional elements. With respect to conventional concrete structures can save time spent in preparing the forms and concrete with the appropriate placement and curing of the latter. Finally it should be noted that these elements pre achieve high quality molded to be prepared at a central facility where they can easily be practiced all the controls are deemed necessary

Table for Prefabricated Panels

.1 .2

1-Description of the machine

1.0.- Product description 1.1.- Generalities 1.2.- Characteristics of each module 1.3.- General plane

2.- Procedure of manufacture

2.1.- Release agent application 2.2.- Placement of partitions 2.3.- Manufacture and placement of armors 2.4.- Discharge of the concrete 2.5.- Terminal and level 2.6.- Shake and removal of panels 2.7.- Table of measures 2.8.- Examples

1.0. Product description

Prefabricated Panels.3 .4

1.1. Generalities

The machine of this manual is called Tilt Table. Used for the production of concrete panels. Basically, it consists of a tubular structure supported on legs of laminated profiles. This structure is manufactured in modules of 12, 12.5 and 13 meters long, with a maximum spacing between supports of 6.25 m. Modules is achieved by joining the table length required by the Customer.

On the tubular structure there goes a sheet of 10mm, which later takes a treatment of polished, and a few bands on both sides of the table that they make the dovetailing one in the plate of concrete. The band performed the female in the concrete is fixed and the male is performing the swing.

The table has a working width of 2.5 meters (optionally can be fabricated from 3 m-3.5-4m) and can manufacture plates 12, 14, 16 and 20 cm thick.

The tilting of the table is by telescopic hydraulic cylinders attached to the support legs.

The regulation plate thickness and the opening of the band folding is done by the same mode by double-acting hydraulic cylinders.

The table is accompanied by a hydraulic control unit and electrical panel from which you perform all these maneuvers.

The set comes complete with a pneumatic vibration facility consists of vibrating independently driven VSP 6623 and collector of 1 “to connect the compressor Customer owns.

1.2.- Characteristics of each module

DIMENSIONS

1. Maximum length: 12 m.

2. Width: 2.5 - 3.00 - 3.50 - 4.00

3. High: Closed: 1000 mm.;

Open: 3310 mm

• Module weight: 2.50 working width: 7,300 kgs, 3.00 working width: 8,000 kg.

• Each leg has a telescopic cylinder expansions ref.419 standard 4 with a run of 1520mm.

• Each table has a series of standard double-acting cylinders:

• 2 units up and down stairs ref thick plate. 705 / 6 600mm of career

• 2 units to open the flip-top band ref.705/3 of 300 mm of career.

QUALITY OF MATERIALS

• Structural tube S275JOH UNE EN 10219.

1. Profile hot-rolled S275JR.

2. Top sheet of 10 mm S275JR.

3. Flame cut plates S235JR.

4. Folded sheets S275JR.

5. Screws quality 8.8.

FINISHES

• Metallic carpentry: a cap of antirust priming and a cap of finished synthetic enamel.

1. Top sheet: polished with stone.

UPN 260

UPN 200

2500

196,5UPN 260 231,5

2500

Tubo 100 x 50 x 5

84°

1000

1.2. General plane


DIFFERENT LINES OF TABLES PREPARED TO RECEIVE THE RELEASE OF CONCRETE

.5 .6

2. Procedure of manufacture 2.1. Release Agent application

Within the panel manufacturing process, one of the most important operations is the application of release agent.

The table surface must be clean of impurities, water and concrete debris. We will use a clean cloth, and give the entire surface of the table.

The application of release agents (type recommended “CHRYSO DEM e-10), is by air pistol, ensuring that the spray pattern in the discharge is as closed as possible, consistent with the pressure, it is advisable to be media/high.

Bathe all trying to cover the maximum surface without causing an over layer.

This operation as mentioned above, is essential for the subsequent stripping of the manufacturing line, in this case panels. This will achieve a good surface finish of the panel and it will prevent us from sticking to the table.

Different lines of tables prepared to receive the release of concrete


2.2. Placement of partitions

This phase will suppose that the panels go out to the measures reflected in the planes.

The dividers can be fixed to the table of two forms: by means of magnets incorporated in his interior (low photos) that prevent the movement of these during the vibrated one; ó with cats for simple dividers.

(To see top photo).

Magnetics separators

2.3. Manufacture and placement of armors

The design of the armor and the types of materials used can be varied. However the armor used conventionally in precast concrete panels (except express customer specifications) will be the type B400S.

B400S type is ideal for corrugated steel arm, equipped with a high ductility, which allows the time to cut and fold, these operations safer and more effective. A number of studies have shown that there are no tears or cracks when the steel is subjected to bending roller / spindles, etc

The armor is composed of: 150x150x6 mm mesh. the entire surface of the plate. H170 perimeter lattice welded wire mesh on. Pin

extraction (2.5 TN. OR 5 TN. As plate) welded to a corrugated bar ø16 mm., Which in turn is welded to provide total body mesh.

The following scheme can appreciate the details of the armor that makes up a prefabricated panel.

Lattice Edge

Fixing bolts

Mesh reinforcement150x150x6

Fixing bolts

.7 .8


The concrete we will do this with gentleness and Cuba shaking or pouring spout so that the distribution is uniform across the table.

Pour the concrete should be avoided with great force, since it could sweep the release agent and we stick to the plate.

The ideal procedure would be poured, carefully, a soft layer of about 2 or 3 cm. around the table, the rest of the thickness can be filled faster then exposed concrete that sits on the plate is the most sensitive in the filling process.

Vat for release of concrete

.9 .10


The concrete used for this process is usually the type HA30 or HA35.

This type of quick-setting concrete is justified by the need for daily stripping of the panels, due to high demand that exists today of these prefabricated components.

The quality finish is guaranteed.

2.2. Placement of partitions

With posteriority to the spillage of the concrete one will proceed to the levelled one and vibrated of the same one. The level is achieved with the “rules vibrant” (see photo). With this transaction we get the intended surface finish on one side of the panel.

Terminal and level

2.6. Shake and removal of panels

The release and removal process is quite simple.

Just bring down the upper band and remove the panels by bolts which, as previously explained in paragraph 4 of armor, we have placed.

For this operation one advises to use a balance beam (to see photo) instead of hooking them with the cables or chains of the bridge crane directly, avoiding disorders and losses of time. Then we will roll slightly forward, so get it off the plate and also put it in the vertical position we want.

Once this process gently remove the panel up, and take you to the bridge crane to the storage place. (See diagram pg. below).

NOTE: It is suitable to leave the panel setting as minimum one week, to proceed to the assembly.

Balance beam

Abat band and remove panel

Step 1 and 2 Step 3

To position vertically

Step 4

Hoisted of the panel to store

.11 .12


Standard measures of prefabricated panels

All the panels are made dovetailing for a correct assembly, both vertical and horizontal. (To see detail)

Panel 12 cm. horixontal 300 12,8 cm. HEB160/HEA160Panel 14 cm. horixontal 350 14,8 cm. HEB180/HEA180Panel 15 cm. horixontal 375 15,8 cm. HEB200/HEA200Panel 16 cm. horixontal 400 16,8 cm. HEB200/HEA200Panel 20 cm. horixontal 500 20,8 cm. HEB240/HEA240

PERFIL ADECUADOTIPO DE PANEL COLOCACIÓN PESO (kg/m2) REGISTRO MÍNIMO

The finish of the panels, regardless of thickness, is composed of a completely smooth face and the other strip or a smooth one with special ending. (See photos page).

Vertical panel assembly

Finished and installed panels(diamond tip)Special panels (diamond tip)

.13 .14

Prefabricated Panels.15 .16

Business

Prefabricated panels