AUTOMATED SYSTEM SOLUTIONS FOR THE MANUFACTURE OF WALLS AND FLOORS:
Double walls:
A double wall consists of two concrete slabs, each 5-7 cm thick, which are held together by truss-type reinforcement embedded in the precast elements.
The space between the slabs is filled with mixed-in-situ concrete. This is why the wall created in the factory is described as a semi-prefabricated element. As soon as it is filled, it creates a monolithic, dense and solid double wall, which is used in basements and on every storey.
Systems technology for double wall production:
◎ Pallet circulation system
◎ Flipping table
Double walls with insulation
Insulated double walls have internal insulation between the concrete slabs, which offers completely new application possibilities and guarantees compliance with the regulations for the thermal insulation of buildings.
Systems technology for insulated double wall production
◎ Pallet circulation system
◎ Flipping table
Sandwich walls
Sandwich walls are used for façades. They are characterised by an insulating layer that is enclosed by concrete on both sides.
On one side there is the load-bearing structure of the sandwich wall with the required static reinforcement, and on the other side there is a concrete coating that gives the appearance of the sandwich wall and the building. This visible coating is often made of coloured concrete or has surface structures of various types.
Technika systemowa do produkcji ścian podwójnych:
◎ Pallet circulation system
◎ Flipping table
Solid walls
Solid walls consist of solid concrete wall elements with a thickness of 10 - 50 cm made of normal or lightweight concrete. The reinforcement that is required for static reasons is installed in the factory, although it often only functions as transport reinforcement, especially in the case of lightweight concrete elements.
Solid walls are used for load-bearing and non-load-bearing basement inner walls and for load-bearing and non-load-bearing ground and ground floor walls.
Compared to a double wall, the main advantage is that no mixed-in-situ concrete is used, allowing construction to progress quickly.
Solid walls used for internal as well as external walls are prefabricated elements that do not require concreting on site when compared to a double wall.
Solid floor slabs are manufactured using a similar manufacturing process as solid wall slabs. They are usually around 20 cm thick and all the necessary static reinforcement is installed in the prefabrication plant. Compared to a precast component floor, the main advantage is that no in-situ concrete is required for construction, enabling construction to go forward faster.
System technology for solid wall & floor production:
◎ Pallet circulation system
◎ Tilting table
◎ Long-line bed and formwork table
◎ Battery mould
Facade elements
Facade elements are industrially produced solid walls that feature a wide range of high-quality surfaces. The spectrum is large and ranges from traditional concrete surfaces with exposed aggregate, through clinker and matrix structures to marbled surfaces.
Often, several types of concrete are used. All reinforcements for the structural stiffness are installed in the factory depending on the intended use. Precast concrete façade elements are very often used as curtain -type (non-load bearing) façade elements.
System technology for façade elements production:
◎ Pallet circulation system
◎ Tilting table
◎ Long-line bed and formwork table
◎ Battery mould
MOTUS hollow core slabs
In hollow core slabs, there are special internal spaces cut out, which significantly reduces their weight. They are therefore an extremely economical solution when taking into account transport and assembly over large areas on the construction site.
In addition, hollow core slabs can be combined with almost all types of walls and ceilings and can be made in reinforced or prestressed versions. Further advantages are the low construction heights for high additional loads and the pore-free view from below.
STANDARD HOLLOW CORE SLABS:
The production of non-prestressed hollow core slabs - also known as DX slabs - allows significant material savings. This is made possible by a weight reduction of up to almost 40% compared to a solid floor slabs. The thickness of a standard hollow core slab is 20 and 24 cm, and the reinforcement is factory-built into the concrete part by the manufacturer.
Advantages from using hollow core slabs:
- can be laid without supports;
- no concrete bedding is required on site (no moisture during construction work); quick assembly: shorter construction time and lower costs;
- quick assembly: shorter construction time and lower costs;
- smooth and uniform bottom layer after joint grouting is ready for further processing (unless the ceiling is equipped with ring anchors - then mixed concrete is required).
System technology for MOTUS hollow core slabs:
◎ Pallet circulation system
Biaxial hollow core slabs
In case of the biaxial hollow core slab, special displacers are introduced to reduce concrete consumption. Only after installation on site the remaining cavities around the displacement bodies are filled with concrete.
The market offers a wide range of displacement systems. The main advantage of this solution is the considerable savings (approx. one third) in deadweight, and the occurring payloads are transferred biaxially. In addition, very large spans are achieved with low structural heights.
System technology for biaxial hollow core slabs:
◎ Pallet circulation system
Filigree slab / Floor slab
A filigree slab is a reinforced concrete slab with a minimum thickness of 5 to 7 cm, depending on the thickness of the concrete covering and the reinforcement. A filigree is a semi-precast element in which the structurally required reinforcement of the lower floor is integrated.
The reinforcement in filigree slabs is resistant to the bending (lattice beams) required for assembly stiffness and to the bending tension in the longitudinal and transverse directions required for assembly and final state.
The in-situ-concrete poured at the construction site completes the filigran slab to form a solid and monolithic reinforced concrete floor. The thickness of the finished floor slab ranges from 12 to 30 cm, depending on the span and load.
The protruding grid reinforcement and the concrete surface itself provide the required anchorage, ensuring good bonding and adhesion between the finished element and the poured concrete.
Apart from some differences in the measurement of the loading force, the floor slab can be seen from a structural point of view to be the same as a floor that has been manufactured on site by pouring mix-in-situ concrete into the formwork. The filigree slab thus combines the main advantages of prefabrication with those of floors produced on site from concrete poured into formwork.
System technology for filigree slabs production:
◎ Pallet circulation system
◎ Long-line bed and formwork table
Columns and beams
Today, modern, large-scale logistics and dispatch centres are being built in ever shorter intervals. Increasingly larger spans and sidewall heights are required in hall buildings to create support-free and space-optimised storage areas. Steel scaffolding is proving to be an inadequate solution in many cases.
Prestressed concrete columns and beams, on the other hand, perform very well. Above all, they are variable in terms of the dimensions and geometry of the elements. This is all the more important as construction today is often no longer standardised and is only carried out using standard parts.
System technology for columns and beams production:
◎ Column mould
◎ Beam mould
TT slabs
TT concrete slabs are used for high loads of 25 kn/sq m and above, which is the case, for example, of wide parking structure floors.
Prestressed floors reach a support span of up to 20 m at constant height. Variants with and without mix-in-situ-concrete are possible.
System technology for TT slabs production:
◎ TT mould
Precast stair
It is difficult to imagine modern residential and industrial construction today without precast concrete stairs. The use of this solution makes it possible to significantly reduce construction time and simplify final assembly. In addition, the consistently high quality of the exposed concrete is guaranteed.
System technology for precast stair production:
◎ Stair mould
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