Moulds for Boundary wall having Designs / Pattern for Wall panel
Length is 6 feet & width is 1 feet Thickness 50 mm / 2"

Video of Bangalore Plant - Panel	Video of Bangalore Plant - Column

Very low on investment, less in weight with same strength because of Hollow cores in the panels, 40% Cheaper, 5 times faster in production, Just by 5 workers, Less Curing time Compared to present concrete casting by mould process, which is very Laborious & Time consuming.

Requirements of Plant set-up to Extrude various types of concrete solid / Hollow core slab as follow: -

1. Land Required: - 1- Acre plus, having length to width ratio of 4:1 or 5:1
2. Land Development & Concrete Extrusion Bed / platform (for extrusion of precast products of non- load bearing types): -Concrete Extrusion Bed / platform is to be made for extrusion of precast products on Well- leveled concrete extrusion bed similar to RCC Road. Width of concrete extrusion bed with each lane is 1mtr. 4 + 4 lanes having length 110 meters long for extrusion of slab & Plus 4 + 4 lanes having length 110 meters for Supporting column. More the length of casting bed it is less laborious & less wastage & can obtain very high efficiency & production. The general speed of Extrusion machine is about 1 meter per minute. The speed is reducing for smaller thickness & if we are casting 2 pcs at a time per lane. In one day with 10 - 12 hrs. Working, total extrusion possible is about 760 running meters with 1 machine. (i.e. 2500 Sq. feet) Usually 4 lane are Extruded / casted say on 1st day & the same are allowed to dry / cure till next day morning. After sufficient curing / drying the precast elements are cut & lifted from casting beds. These casting beds are then cleaned, oiled & prepared by stressing wires for following day.
   Similarly on the second day the next 4 lanes are used for extrusion / casting & are allowed to dry / cure etc. This cycle goes on & on for mass production.
   Concrete extrusion bed is made-up of M40 grade of concrete having zero - zero level & very hard & smooth surface in order to achieve good surface finish at the bottom. The Depth of casting platform having M40 grade of concrete is about 100mm + having 8 mm Dia. reinforcement of steel bars & with Abutment at 2 ends of concrete extrusion bed. Rest area can be paved.
3. Power: - 35 Kw is required for panels
4. Water: - 8000 – 10,000 liters /day.
5. Labour: - 12 nos. (skilled & unskilled depending upon no of extrusion m/c).
6. Raw Material: - Portland cement + River Sand or Crushed sand free from fines confirming to Zone 2 + Aggregate - strictly well sieved of size 6-10mm.
7. Machines: - Extrusion machine for panel of 50mm thick x 300 mm width x 2 Plus Corner Supporting Pillar / column having slots at right (Please note: - 1 Extrusion m/c can only produce 1-Size of precast element.)
8. Common Supporting machinery: -
1. 17.5 CBM (350 Liters) Single cylindrical concrete Mixer suggested by us. Please note: - Drum mixer cannot be used for making very good homogenous zero-slump concrete for extrusion. Optional by Concrete Batching & Dosing equipment + Cement silo with cement conveying feeder + Water, Additives & Cement metering pumps & weighing hopper plus Semi-automatic control.
2. Tensioning / Stressing m/c with Anchor clips for carbon steel wire.
3. Manually operated Feeding cart for concrete mix delivery to extrusion mc – 2 Nos.
4. Slab Cutting m/c suitable for panels & column.
5. Wire Coil Dispensing stand – 1 nos.
6. Optional - Woollen & Plastic Insulation Covers to cover the Extruded slab.
7. Optional - Need equipment for lifting & shifting m/c. For placing it on casting bed from 1 lane to another & for placing on mild steel fabricated stand for washing.
8. Trolley - for shifting precast products & other small accessories as per list etc.

The Basic work flow for concrete Extrusion of slabs for Light-duty & Heavy-duty Boundary wall Panels or Supporting column i.e. ‘H’ / ‘I’ section 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 & water of M20 or M25 grade 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 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 analysed.
9. Once the slab is cured Mark & Cut with Slab cutting m/c to make panels or columns of required lengths as per order.
10. Lift Panels or column & 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. For more profit & to make it economical 2 Nos. are extruded at a Time per lane of Boundary Wall Panels OR Supporting Column. The extrusion speed of the machine is between 5 feet / 6 feet per minute. The Extrusion casting per lane will take around maximum 45 minutes depending on the length of the casting lane.
14. Zero Slump Concrete is used for Extrusion, Where Water Cement ration is just 0.3%. As Extruder needs to be fed continuously with dry concrete, 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 or foundry slag.
17. The steel wires also help in the rigidity during loading, unloading, lifting and installation.
18. List of machinery required: - Extrusion M/c for Panel - 1 No. + Extrusion M/c for Column -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 Panels for Partition Walls, 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 Boundary wall.