What makes a casting wall production line efficient?

Elematic is well known worldwide for hollow-core technology, but the company also has a strong product line for casting wall elements, with three turnkey sectioning concepts (the SEMI, PRO and EDGE) for variation in automation degree and production capacity.

But as Toni Koitmaa, product manager of wall technology at Elematic explains "There are many solutions possible. "We have many other partitioning options for varying capacities and these do a great job in many current manufacturing plants. Our strength lies in our solutions with customized wall production."

A full range of wall production equipment

One device that seems to make wall production lines significantly more efficient is the central transfer cart, especially when the product pallet includes both simple, fast-moving elements and complex panels that require more production time. "The central cart moves the elements that require more production time away from the main line, avoiding bottle necks in production. This allows the faster-produced elements to come forward, and production runs very flexibly, "Koitmaa explains.

Predefined processes and good documentation throughout the production process are important for consistency in production and quality management. "For example, table molds are a long-term investment. You have to guarantee that the molds can meet the requirements set for the wall element. Table dies must be flat and straight and must support the load placed on them without sagging. It takes a lot of experience to make mold tables within strict tolerances." says Koitmaa.

The casting machine is another essential piece of equipment. Elematic's Comcaster is, in Koitmaa's words, "very unique, very accurate and fast" and allows for a lower water-cement ratio. It can also make harder concrete than conventional casting machines and reduces surface finish time.

Goals such as less waste in the casting production process and better efficiency and safety are also continuously pursued. "With the right shutter system, you can use half the amount of wood necessary for table dies, battery dies and column and pillar production. The FaMe system consists of push-button magnets and aluminum side molds that replace wood and steel, and that leads to substantial savings." Koitmaa adds that the FaMe system was designed to increase work safety and reduce the chances of finger injuries.

Battery dies (used to cast solid load-bearing walls) can also have a big effect on efficiency. The cold shutter system (supplied by a very small number of machine manufacturers in the industry) has almost double the capacity of a standard battery die. The casting cycle is significantly reduced by transferring the cold-closer plates to the battery die after the previous casting elements are removed. "The cold shutter system significantly speeds up the production cycle because only casting and curing take place within the battery die. This achieves significantly higher capacity." explains Koitmaa.

Digitalization also brings top efficiency significantly closer. "With the help of digital systems, you can realize the maximum capacity of casting lines by optimizing the process at different stages of production, and this leads to faster delivery time and resource savings." promises Koitmaa. At this year's BAUMA, Elematic introduced the WallMES, as part of its digital plant control for casting plants.

Multiple tried and tested on the factory floor

Some examples of working Elematic circulation lines:

Elematic production line helps change cityscape in Nizhny Novgorod region of Russia. Karkas Monolit's line has a capacity of 280,000 square meters per year, with 40 tables, 3 concrete transport shuttles, a transfer truck, a gathering station, a tipping station and a transport truck. Their plant is the largest in the region.

Block Berge Bygg AS in Norway, with production accounting for 15 percent of the total concrete elements market in Norway, purchased an Elematic circulation line with a weekly capacity of 1,500 m2.

Santalan Betoni in Finland has also invested in Elematic's circulation line for their new casting wall plant. The line includes 26 tables, a Comcaster E9 casting machine, tilting tables and two transfer cars.

The Elematic wall production lines

SEMI, for cast wall production between 70,000 and 150,000 m2 per year. SEMI Wall has a straightforward and easy-to-learn basic technique.

Theoretical capacity: 280-600 m2/day (one casting)

Employees: 10

Production area: 2000 m2

Land area:20,000 m2

Number of tables: 10-15

Average table size:3.5 x 8.0 m

PRO, for casting production with an annual capacity of 170,000-300,000 m2. All major PRO functions are automated. The PRO Wall line consists of a circulation line and optional battery dies and tilt tables.

Theoretical capacity: 680-1200 m2/day (one casting)

Employees: 12-20

Production area: 2800 m2

Land area:45,000 m2

Number of tables: 20-30

Average table size:3.8 x 9.0 m

EDGE (for very high capacity, annual 400,000-750,000 m2) with large product range and highly automated casting production. For high productivity, tables move automatically between production steps. Logistics is cleverly solved with a central transfer truck that guarantees smooth movement. Productivity is further enhanced by fully automated concrete transport and an automatic sealing station.

Theoretical capacity: 1600-3024 m2/day (one casting)

Employees: 30-35

Production area: 9000 m2

Land area:70,000 m2

Number of tables: 40-60

Average table size:4.0 x 10 m

All figures are calculations