The Elematic Acotec SEMI production line offers straightforward, fast and profitable production technology for light, non-load bearing, room-high partition walls.
The line covers the entire production process from concrete batching all the way to overnight storage.
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Acotec SEMI line
|Theoretical capacity||80 m2/h|
|Production area||900 m2|
|Land area||3000-5000 m2|
|No. of plates||50 pcs (extras as option)|
|End product length||2200-3300 mm|
|End product thickness||68-120 mm|
|End product width||600 mm (2x300 mm also available)|
The Acotec SEMI line produces light, non-load bearing, room-high partition wall panels 2 200 mm to 3 300 mm long and 68 mm to 120 mm thick. It produces panels 600 mm wide, or as an option, 2 x 300 mm wide.
The SEMI is a basic line with a production capacity of 80 m2/hour*. On an annual basis, this gives it a capacity of 140 – 170 000 m2 in one shift operation – enough to build partition walls for 1400 – 1800 dwellings.
The SEMI line only needs an area of 900 m2 for production, and the total land area required for operation is 3 000 – 5 000 m2. It requires 5 to 7 personnel to operate the line. The line can also be installed in existing facilities.
*Peak capacity. Maintenance stops (2 to 4 per shift) etc. not included.
The Acotec SEMI features automated key functions: casting, sawing and stacking. Restacking and plate handling are semi-automatic, and non-critical functions are manual.
The key equipment on the SEMI line includes a fast, reliable and easy to maintain stationary extruder with three vibrators, and compression and levelling equipment. The extruder is equipped with standard panel thickness sets of 68/75/85/92/100/120 mm according to selection. A moving circular saw is installed on a roller conveyor which cuts at a speed of 10 m/min. The stacker stacks the extruded products and their backing plates in 4 to 10-piece stacks on steel pallets and transfers the pallets for precuring. The restacker-handler picks up the finished products and feeds the plates to the extruder, while separating B-quality panels.
ACOTEC LINE TECHNOLOGY
Like all Elematic Acotec lines, the SEMI is simple to install, run and maintain. It features an advanced production control system and a simple, modern user interface which displays detailed data about every function in the process. Various real-time reports –production rate, running hours and more – are generated automatically. Each line is built from proven, standard components for highly reliable operation.
The line’s modular structure and integrated electricity with ETHERCAT bus system guarantee a short installation and start up time.
Acotec panel production on the SEMI line takes place in the following steps:
• Batching and mixing
• Restacking & plate handling
• Cleaning (manual, automatic optional)
• Returning pallets
• Packing and delivery
The Acotec panel production process starts with batching and mixing of concrete at an automatic batching and mixing station. The aggregates are automatically batched into the mixer, after which cement, and water are added into the mixture. After mixing, the concrete batch is fed to the conveying system and conveyed to the line’s hopper.
The panels are then formed by a continuously operating extruder. The concrete is compacted onto thin base molds which are then automatically fed into the extruder as a continuous ribbon. The extruder compacts the concrete with extrusion screws and the top surface of the product is vibrated by a vibrating plate.
After extrusion, the panels are cut according to the base mold length. The circular saw cuts the fresh concrete on each base mold seam on the fly. The cut panel together with the supporting plate is pulled to the stacker and stacked onto precuring stacks and moved to the precuring area, where the temperature should be above +10°C. The cut panel can either be transferred using an automated conveyor system, or with a forklift or a crane. The stacks stay in the precuring area for 15 to 24 hours. In a dry climate, the stacks should be covered with tarpaulins.
After precuring, the panels are removed from the mold plates. The plates are manually cleaned and oiled, and then the restacker-handler moves the clean mold plates to the storage stacks and feeds them back to the extruder for casting. The panels are restacked in stacks of 4 to 10 units for delivery. The delivery stacks are strapped and preferably wrapped before transportation to delivery storage. The stacks must stay in delivery storage for at least 14 days before being transported to a construction site.
Automatic mold plate cleaning is available as an option.
The Acotec production method is environmentally friendly. The raw materials used are natural materials – just water, sand, cement and lightweight aggregate. The production process does not need any additives or chemicals.
The concrete waste produced is kept to a minimum: rejected panels can be recycled back into the production process.
All machines on the Acotec SEMI line meet EC Machine Directive requirements. The line is equipped with multiple safety light curtains and all doors have safety sensors. The machinery is designed to keep noise levels low and ensure safety with their flat outer surfaces. The line comes with thorough and clear user, maintenance and safety manuals in the required language.
Product module 8/68, 8/75, 6/92, 6/100, 6/120
Thickness set 68, 75, 92, 100, 120
Splitting set 2 x 300 / 68, 75, 92, 100,120
Extra mold plates
Extra steel pallets
Batching and mixing plant and concrete transport system
Cleaning and oiling