EDGE Wall Production Line
High factory capacity, top-rate product quality and reduced operating costs
Batching and Mixing
Concrete production is the core part of the precasting process. This is done by mixing cement, sand, and other aggregates with water and sometimes also with additives prior to molding. In EDGE Wall production line this is done by Batching and Mixing Plant E9-105.
Elematic concrete transportation systems transport concrete to the casting station of a precast factory. The system consists of tracks and shuttles in the needed amount. The track is electrified and the system functions automatically. The transportation in EDGE Wall production line is handled by Shuttle E9-2800.
The shuttering robot will automatically place side forms on their right positions based on wall panel CAD drawing. Possible window and door openings are placed manually by using FaMe shuttering method (aluminum side forms and magnets). After all shuttering is placed on their position reinforcement and other inserts will be added on the table. The shuttering process in EDGE Wall production line is taken care of by Plotter E9-4.0x10.0, Automatic Shuttering Station E9 and FaMe -set.
Casting and compaction
Table is moved to the casting machine where the concrete is cast to the table. At the same time compaction station is used for compacting concrete. For insulated products, the insulation is laid on top of the first cast layer and thereafter the second layer of concrete is cast. The casting and compaction in EDGE Wall production line is done by Comcaster E9-2500 and Compaction Station E9-30c.
After casting and surface finishing the tables are moved to curing chamber. Curing chamber is equipped with roof, walls and lifting doors to prevent heat and moisture loss. Chamber can be equipped with a heating system. The curing chamber in the EDGE layout includes 60 curing places. The EDGE Wall production line includes Lifting Device E9-30l for lifting and pushing the tables into the right position and back to floor position.
All the shuttering is removed from the table and it is tilted up at tilting station. Ready made precast products are lifted up by lifting beam connected to an overhead crane. Tilting Station E9-30t is used in EDGE Wall production lines.
Wall surface finishing
Due to different surface and quality requirements, the product needs to go through a product-specific finishing work before it is transferred to the storage yard. The finishing work can be made either inside the production halls or in the storage yard.
Table cleaning and oiling
The table preparation in EDGE Wall production line is carried out by Cleaning Machine E9-4.0c and Oiling Machine E9-4.0o. First the table will be cleaned by brushing unit of cleaning machine and then it will be oiled with oiling unit.
Storing, lifting and transferring
Finished products are transported with wagons to the storage yard. There the products are lifted with cranes to locations assigned by ELiPLAN’s storage management. The storing, lifting and trasferring in EDGE Wall production line is done by Lifting Beam E9-10-6.5 and Transport Wagon E9-40.
The fully-automated Elematic EDGE Wall offers clear benefits:
- Straightforward and easy production optimization and material management - materials are directly synchronized with product design information.
- Consistent and high production capacity
- Centrally controlled and monitored line operations, with real-time production data available at all times for any possible product adjustment needs.
- High productivity with product-specific table routing
- High quality tables with smooth surface for top-rate product quality and minimal finishing work
- Tracking of finished products
EDGE Wall automation can be integrated with CAD or BIM software to support the complete workflow from building design up to erection at the construction site. Manufacturing details and deliveries can be tracked at the construction site by using an intuitive 3D view of the building.
1. Batching and Mixing
2. Concrete transportation
4. Casting and compaction
7. Wall surface finishing
8. Table cleaning and oiling
9. Storing, lifting, and transferring
Elematic EDGE Wall production line is an ideal solution for anyone looking for high factory capacity, top-rate product quality and reduced operating costs. Elematic EDGE offers all this through its state-of-the art automation technologies, optimized production plan, carefully-designed production process and individually tailored solutions.
EDGE Wall consists of manufacturing execution system, automatic machinery and table circulation system. Manufacturing execution system helps planning the optimal use of production capacity, monitoring the production status and controlling factory operations.
EDGE Wall production line suits particularly well for the production of sandwich panels, cladding panels, solid panels and solid slabs.
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