Concrete Hollow core Panels / Planks for making Partition Walls is a fast & easy solution which is implemented worldwide for making Partition walls against the time consuming, highly labour oriented & tedious process of making walls AAC / CLC / Concrete Blocks, bricks etc. Plus 30% Cheaper, Project investment is very low (about Rs. 55 Lakhs all inclusive compared to European plants of 14 corer), Requires only 13 workers, Less in weight with same strength because of Hollow cores in the panels, Dry wall, Saves steel used in building project. Good Moisture Resistance, Excellent Resistance in wet condition.

1. Land Required: - 1 - Acre plus, having length to width ratio of 4:1 or 5:1. On this land make a well-level concrete platform (make similar to good quality of concrete Road) for extrusion of Wall Panels. Concrete platform can be 360 feet long x 30 feet width for 8 lanes or 360 feet x 15 feet for 4 lanes plus on the two ends of concrete platform need to fix / grout Abutment plates (lengthwise) for placing carbon steel wires of 3mm to 5mm dia. for reinforcement of panels & stressing it.
2. Power: - 60 Kw is required for panels.
3. Water: - 10,000 liters /day.
4. Plant Electrification, Water, and Plumbing & Drainage Etc.: - a). Electrification: - Need 2 points of 3 phase for connecting Extrusion m/c & Slab Cutting m/c + 15 amp 2 electrical points for repair & maintenance on 2 longitudinal parallel side. Plant Illuminations + Power Cables required for Extrusion M/c, Gantry Crane, Slab Cutting Machine, for Batching Plant. Power cable Specification 4 core 16mm Approx. 200 Meters. Add Plant illumination cost, if plant is not open to sky. Buy D.G.Set of 60 KW if power supply is not regular.
   b). Water & Water Storage Tanks: - for Slab Curing, Cutting of panels, washing of m/c’s & for Batching plant Approx. 5,000 Liters of water required every day. (Water tank of 5000 liters capacity buy 2 Nos. = 10000 Liters). Water used for batching & mixing plant should be Salt free & required about 1.5 cubic meters / hour. Buy Water hose pipes with quick connecting coupling + cost of Jet water spray with pressure pump & motor for Washing Extrusion Machine (similar to used for car washing)
   c). Plumbing: - Outlet required for Slab Curing & Cutting of panels at least 2 outlets. 1water points each on longitudinal parallel sides. Water Hosepipe should have Quick connecting coupling at their ends for easy operation. d). Drainage & other detail on all above will be given in drawing along with its layout suitable to your land after receiving your order along with advance.
   
5. Machines: - Details of Wall panels Extrusion M/c: - Thickness of slab - 100mm, Width of slab -600mm, Number of cores: -7 Nos of 58 / 60mm dia.
   The Extrusion technology used is Auger type compressing form method to make a good structure of wall panel & with good surface finish, which is further, vibrated & compacted in the front of the m/c. The m/c while casting takes guide of the M.S. Patti fixed on the ground.
6. Labor: - 16 nos. (Stressing & Extrusion m/c Operator – 1 + 2 helper per machine, Batching Plant Operator – 1 + 1 helper, 1 Wheel Loader operator, manual cart operators – 2 & for lifting & shifting – 7 & 1 Quality control.
7. Raw material for making Panel: - As the panels are extruded with Hollow cores it is 35% light in weight compared to solid concrete panels, but in order to make it further Light in weight, for ease in handling & reduce dead load on floor slab use LECA as against Aggregate (Light-weight Expanded Clay Aggregate).

Product Dimension: - 100 mm Thick X 600 mm Wide X Length to cut without any wastage from slab. These panels are reinforcements with 4 Nos. of carbon steel wires of 3 mm diameter (weight of 3 mm dia. wire is 0.0554 kg per meter). Panels of 100mm thick have Cylindrical Hollow cores incorporated with 7 Nos. of 58mm dia. The concrete quantity per cubic meter for 1 meter long slab is 0.054 Cubic meters minus 7 nos. of 58mm Dia core i.e. 0.01849 Cubic meters. Hence Total Net concrete Quantity per cubic meter is 0.03551 m3.

Theoretical Weight of Panels: -

1. Conventional Concrete having density of 2,400 kgs / m3 The weight of panel size of 100mm Thick X 600mm Wide is around 180 Kgs / meter square & for 2740mm (9 feet) long is 300 Kgs.
2. Light Weight Concrete for Concrete Mix of 1,500 kgs / m3 while using LECA of 4 to 8mm size. The weight of panel size of 100mm Thick X 600mm Wide is around 10 Kgs / Sq. Ft. / meter square & for 2740mm (9 feet) long is 180 Kgs.

The Basic work flow for concrete Extrusion of slabs for Wall Panels is as follows: -

1. Preparing the concrete platform / casting beds by cleaning & oiling.
2. Carbon Steel wires are pulled from coils & placed for stressing (size as per length of bed) at Live end & Dead ends of the Casting platform.
3. Pre-stress Carbon Steel wires with Stressing equipment.
4. Prepare concrete mix using Cement, Sand, Aggregate below 8mm or LECA or foundry slag & water in a Cylindrical Mixer.
5. Using 2 nos. of Battery operated Mini Dumper / Manual cart Fill the hopper of Extruder m/c. with above Concrete mix into continuously.
6. Run Extrusion m/c from one lane of casting to another lane as per instruction & cast wall panel slab around the Carbon Steel wires.
7. Water the slab & then Cover it for Fast & better Curing.
8. For Quality Check, Test block casted along with extrusion of slab is to be analyzed.
9. Once the slab is cured Mark & Cut as per room height with Slab cutting m/c to make Wall panels for Partition walls.
10. Lift Panels & Move it form concrete platform for further Curing or storage or dispatch.
11. In a dry climate, the stacks of Panels or column should be covered with plastic cover / tarpaulins.
12. Clean & wash all the machine & equipment as per instruction.
13. The extrusion speed of the machine is between 5 feet / 6 feet per minute. The Extrusion casting per lane will take around max. 45 minutes depending on the length of bed.
14. Zero Slump dry Concrete is used for Extrusion, Where Water Cement ration is just 0.3%. As Extruder needs to be fed continuously with dry concrete mix as per design, it is advisable to buy good Cylindrical Mixer & not Drum mixer.
15. For High volume of Production you require Batching & Dosing Equipment & Cement Silo.
16. To make it more economical you can add small portion of fly ash.
17. The steel wires also help in the rigidity during loading, unloading, lifting and installation.
18. List of machinery required: - Extrusion M/c for Wall Panel - 1 No. + Complete Concrete Mixer on stand & platform (i.e Cylindrical in shape & shaft rotating in horizontal plane) + Stressing M/c + Mini dumper / Manual Feeding Cart + Slab Cutting M/c + Dispensing stand for carbon steel wire + M/c lifting & shifting trolley.

Additionally Manufacture other concrete products like Light series of pre-stress load bearing hollow core slab use in affordable housing, Use above wall panel for making Boundary wall along with Supporting “H” Column, Beam, Column, Lintel, Fencing post, ’T’ beam, Purline with respective Extrusion m/c on the same concrete platform while using Supporting machinery & other facility of Wall Panel.

Extrusion Machine for Wall Panels or Light Loads on Slabs

Extrusion M/c for Supporting 'H' Column for Boundary Wall

Abutment, Stressing & Coil Dispensing Equipment

Concrete Mixer - Cylindrical & Batching / Dosing Equipments

Concrete Transporter - Manual Cart / Mini Dumper

The Battery Operated Mini Dumper is driven directly below the mixer of batching plant for collection of the concrete mix. As the bucket is mounted on back side of the vehicle one can view & control while unloading concrete mix into the hopper of extrusion machine.

Slab Cutting Machine

Lightweight Material - LECA / Foundry Slag / Flyash Aggt

LECA is a special type of light aggregates that has been pelleted and fired in a rotary kiln at a very high temperature. As it is fired, the organic compounds are burn off forcing the pellets to expand and become honeycombed while the outside surface of each granule melts and is sintered. The resulting ceramic pellets are lightweight, porous and have a high crushing resistance

Cranes & Lifting System

Lifting Lightweight Hollow core Wall Panels with Swivel Crane is most Economical, Flexible & ideal compared to Gantry crane or any other lifting system.

Manufacturing Cost, Project Report & Download

PDF File - Production Cost Analysis on Pre-stressed Precast Concrete Hollow Core Lightweight Wall Panel Slab

Automated Plant for Wall Panels similar to European