The Production Process of the Concrete Wall Panel Machine/prestressed lightweight wall panels involves multiple steps:
1. Raw Material Preparation
Cement: Select high – quality cement that meets national standards as the basic binder. Its strength grade is an important factor to ensure the final strength of the wall panel.
Lightweight Aggregate: Materials such as expanded perlite, expanded vermiculite, or polystyrene particles can be used. These lightweight aggregates reduce the density of the wall panel. For example, expanded perlite has a porous structure, which can effectively lower the overall weight.
Additives: Utilize water – reducers, retarders, and early – strength agents. Water – reducers can reduce the water consumption in the mixture while maintaining workability, thereby increasing the strength of the wall panel. Retarders are used to control the setting time, especially in large – scale production. Early – strength agents can accelerate the early – stage strength development, shortening the production cycle.
2. Production of Prestressed Reinforcement
Reinforcement Selection: Choose high – strength steel wires or steel strands. The strength and ductility of these materials need to meet strict requirements to provide sufficient prestress for the wall panel.
Stretching Process: Fix the selected steel wires or strands on a prestressing bed. Use a hydraulic jack or other stretching equipment to stretch them to a predetermined stress level according to design requirements. This pre – stretching is crucial as it imparts prestress to the wall panel, improving its crack resistance and load – bearing capacity.
3. Mixing and Production
Mixing of Materials: Put the prepared cement, lightweight aggregates, fibers, additives, and water into a mixer in a certain proportion. Thoroughly stir them to obtain a homogeneous mixture with good fluidity and workability.
Production: Pour the well – mixed material into machine hopper with prestressed reinforcement. Then machine start to vibrate and extrude,Then wall panel can be made.
4. Initial Curing
Covering and Moistening: After extruding, immediately cover the wall panel with a plastic film or other moisture – retaining materials to prevent water evaporation from the surface. Keep the surface moist by spraying water regularly to promote the hydration reaction of cement.
Temperature Control: In some cases, especially in winter or in cold environments, it is necessary to control the curing temperature. Warm maintenance methods such as steam curing can be used to ensure that the wall panel reaches a certain initial strength within a short time.
5. Prestress Release
Strength Detection: When the wall panel reaches a specific strength (usually determined by design requirements), use a strength – testing instrument to check whether it meets the prestress – release standard.
Release Operation: Use special equipment to gradually release the prestress on the reinforcement according to a specific process. During this process, the deformation of the wall panel needs to be monitored to ensure its quality and safety.
6. Final Curing
Natural Curing or Kiln Curing: Natural curing involves placing the wall panel in a natural environment for a certain period, usually more than 28 days, to allow it to continue to gain strength. Kiln curing can significantly shorten the curing time. Place the wall panel in a curing kiln and control the temperature and humidity according to a set curve to accelerate the strength development process.
7. Quality Inspection
Appearance Inspection: Check the surface of the wall panel for defects such as cracks, honeycombs, and pockmarks. The size and shape of the wall panel also need to be measured to ensure they meet design specifications.
Physical Property Testing: Conduct compressive strength tests, flexural strength tests, and density tests. These tests are used to evaluate the mechanical properties and lightweight performance of the wall panel to determine whether it meets relevant standards and engineering requirements.
8. Packaging and Storage
Packaging: Wrap the qualified wall panel with protective materials such as plastic film, carton, or wooden frame. Packaging can prevent damage during transportation and storage.
Storage: Store the wall panel in a dry, well – ventilated place. Stack the wall panels in an orderly manner and take appropriate support and protection measures to prevent deformation and damage.
Above is the basic process of concrete wall panel production, welcome to contact us for more details if interested in this technology.
