Requirements to set-up a Plant for Hollow Core Load Bearing slabs / planks: -

To set up 4 casting beds and storage you require maximum space of 140m long X 7 m wide = 980 sq meter. It also requires an additional area of about 6600 sq meter (1.5 acre) that has to be duly well compacted and cemented or paver block for batching plant, raw material, finished goods storage, office, Qc , laboratory department and also for the repair and maintenance.

For setting up a hollow core plant one need to have approximately 200kw (270HP) of power.

5000 liters of water is used in the process per day and it should be free from salt.

One should use the normal Portland cement or high early strength cement because they contribute to workability and benefit the rapid curing.

Sand should be clean & confirmed to zone 2 or equivalent.

The aggregates of high density of an irregular shape of size 8/12mm (Max14 mm) are recommended. The extremes of a very rounded or extremely angular respective are more prone to sagging and it lower speeds or are difficult to compact.

The planning of the plant should be done for both short term as well as long-term capacity along with the number of beds and its length. The normal bed length can vary from 130 to 150 meters. The factory layout must have provision for future production levels to meet market demand without disrupting the ongoing production. Longer the size of the casting bed better the planning & lesser wastage of concrete, steel wire strands, labor and above all time.

It should also consider the handling, storing, distributing maintenance and services of the finished products and concrete batching. Because of adequate time available one can use that time for curing, cutting, lifting of slabs and also for cleaning & preparing the beds for casting again.

Curing time is very important in production cycle, as the strength of the concrete must be adequate enough to hold the bond between steel wire strand & hollow core slab before cutting it.

Before setting up any plant what are really needed are Product specifications:

• For Residential / commercial / Industrial Use.
• The required loading capacities & span
• Thicknesses of slab
• Cutting Length
• Design requirements for openings etc. (askew ends, corner cuts, holes etc.)
• Marking (Identification)
• Requirements of standards

Technical specifications

• Mixing plant suitable for homogenous zero slump concrete
• Concrete transportation fast and reliable
• Cranes heavy enough
• Lifting beams and clamps suitable for all production
• Casting beds are basis of product quality
• Basic layout for continuous operation
• Design & Drainage holes requirement
• Safety requirements
• Maintenance arrangements