Economical Solution - Pallet circulating system by Central Shifter

New Economical concept compared to fully automatic PCS. (Ideal to install at project site.)
(Movable precast plant is Low on Investment, Expandable and Flexible) Most economical concept for production of Precast elements like: - Load bearing Walls & Slabs, Half Slab / filigree slabs, Double walls, sandwich wall and other special elements etc.
High flexible & has cycle-free workstations. Here the pallets are transported / moved between workstations to workstation either manually or with the help of central shifters for shuttering, reinforcement, concreting, Vibrating /compaction, leveling, trowelling, curing & tilting.
The pallet can be slide manually or to driven by Friction drive wheel, as they are mounted on Roller blocks. Working areas are coordinated & combined at individual stations: - a). For preparation of the pallets, b). Casting, Vibrating/compacting, leveling c). Smoothing / Napping, d). Curing of elements & e). Stripping and pick-up of elements. The defined working areas also enable optimized logistics and the preparation of materials. Furthermore, the station’s offer adaptability on account of the ever-changing range of demands that they have to meet. Pallet circulating system / Carrousel systems using central shifters can be gradually expanded as per requirement in the existing set-up up to 100 pallets.
Here pallets are Transported / moved from Workstation to work station for shuttering, reinforcement, concreting, compaction, leveling, trowelling, curing & tilting with the help of Central / Side Shifter.

Advantages: - of Economical Concept for Pallet circulating System

1. It is Mobile Plant can be installed (Open to sky or with temporary shed) at project site with Tilting station, just outside the production area but in the yard under gantry crane for lifting element & storing in Stock-yard.
2. Concreting on pallet for precast elements can be done by Speedy truck or on Concreting & Compacting station. (Speedy truck operates on diesel. Costly Concrete Skip / Bucket & Concrete Spreaders are not required for concreting if one is using Speedy truck)
3. Only 1 Vibrating Stations & 1 Tilting station is required instead of multiple Tilting tables & it’s Vibrators. Even installation & dismantling work is reduce
4. No gantry crane is required in the plant (Only 1 or 2 gantry crane required in stock yard). As Central Shifter can do all work of gantry crane.
5. No transport carriages to bring out the ready elements of the factory are needed can be done by Central Shifter.
6. If the space is large enough one can do Natural curing, as our climate is hot & humid
7. Very less wiring required hence less complication.
8. Very less power required.
9. Spares required is very less as fewer equipment’s are used compared to standard carousal system.
10. Very easy to move Dismantle & Transport plant as there are fewer equipment etc. like Pallets, Tiling table, Central shifter, Rollers and rails can be easily removed.
11. Expansion for more production is very easy
12. Installation of plant can be very fast & easy to maintain.
13. Foundation only needed for a). Concreting & Compacting station. b). Tilting station.
14. Every working station can be optimized for each process

Requirements to set-up Precast Concrete Element Plant: -

For Maximum annual production capacity of say 2,50,000 m2 / year of Precast Concrete elements like Solid load bearing External walls, solid floors, Double layer walls or precast elements with core insulation, Partition walls / Internal wall panel, Composite slab panel, Beam, Column, Staircase, Double Tee, Balcony compound wall etc.

For best production facility with expansion plus in future setting –up of Hollow core slab production & storage, a good size of Precast Concrete factory area Totally required is about 70,000 – 1,00,000 square meters. (Say 25 acres).

About 170 meter x 25 meters - 2 bays are required for Precast Concrete elements production workshop. One line is the ‘standard part production line’ for standard parts; the other is the ‘special part production line’, which caters for the time-consuming operations such as fitting special reinforcement, required for special precast elements. Where jobs require an especially flexible response the pallet can be moved across to the other production line. On one line pallet circulating system is fitted & on other bay is for Special elements, Beam & Column, Double Tee, Tilting Tables & Battery mould etc., (Based on pallets with dimensions of 12 x 4 meter & At an utilization rate of 60 to 80% this allows the manufacture of approx. 25 to 30 m2 precast concrete parts per pallet per hour)

Attached with above plant 5,000 m2 for Concrete Batching & mixing plant (Approx. 180 m3/hr.) with storage of aggregates, sand & having 2 - 4 nos. of Cement silos etc., Steam boiler plant, Area for Reinforcing preparation workshop with Tools for cutting & forming steel reinforcement along with Steel fabrication & general workshop machinery for repair & maintenance, general store area plus finish good storage area 30,000 – 50,000 m2, Quality control dept., beside this, it also need to consider Administrating Building with all utilities, Staff Quarters.

Other requirements are Drinking Water storage tanks & pump house, Transformer sub Station for 1500 - 2000 KVA, Weighbridge - 60T, Good internal Road etc. plus vehicles, Trucks, Wheel Loader, forklift & Cranes etc. Full load production personnel required is approx. 200 - 400 nos. And roughly construction period required for above is 4 - 6 months minimum.

This allows the company to cater to Residential housing, commercial and Industrial construction needs, including modular products for schools, and many speciality products in addition to floor slabs and walls.