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Cement Foam Wall Panel Production Line1
Building Material Making MachineryBoard Making MachineCement Foam Wall Panel MachineWall Panel Machine
Henan Zhihao Industrial Co., Ltd.
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Product Description Introduction to Cement Foam Wall Panel Production Line The products produced on the production line-cement foam wall panels Cement foam wall panels are made by quickly mixing cement, fly ash, water, additives, fiberglass mesh, and pre-formed foam in a specialized mixer, then forming them into lightweight wall panels using a set mold. These panels are used for non-load-bearing partition walls in industrial and civil building projects.01.Reinforced steel frameThe steel-reinforced concrete structure, formed by combining rebar frameworks with lightweight aggregate concrete, enhances the bending resistance, crack resistance, and overall performance of the wall panels. This type of wall can be drilled or cut without affecting its strength, while also offering high hanging capacity (with single-point hanging strength exceeding 300 kg) and excellent impact resistance.02.Strength and densityThe strength and density of aerated concrete wall panels are well-balanced, with a strength of over 7 MPa and a density of around 1000 kg/m3. By maintaining a reasonable density, the wall panels achieve high strength, which is their standout feature. This high strength significantly enhances various properties of the wall panels, such as hanging capacity, impact resistance, and sound insulation.03.Fire resistance and sound insulation performanceDue to the excellent fire-resistant properties of the steel-reinforced expanded clay concrete material, the wall panels meet or exceed national standard A-level fire resistance. Additionally, they do not produce any harmful gases when burning. The fire resistance limit of 100mm thick expanded clay concrete wall panels can reach over 2.5 hours. Expanded clay itself is an excellent thermal insulation and soundproofing material, and combined with the dense structure of concrete, it also provides excellent soundproofing performance. The 100mm thick expanded clay concrete wall panels can achieve a sound insulation level of 45 dB.04.Excellent water and moisture resistanceLightweight aggregate reinforced concrete panels, similar to regular concrete in internal structure, possess excellent waterproof and moisture-resistant properties. They can be used in areas such as kitchens, bathrooms, and basements without issues like moisture absorption leading to softening, efflorescence, deformation, or strength reduction. Therefore, the waterproof and moisture-resistant performance of these panels is significantly advantageous compared to other types of wall panels or blocks.05.Excellent hanging performanceAt any point on the aerated concrete wall panel, cabinets can be installed with anchor screws, they can also be hung or have marble mounted externally. The wall panel has a single-point suspension strength of 300 kg, and the anchoring components remain in place without loosening or falling off.06.Excellent impact resistance and crush resistanceAccording to the testing method specified in the national standard JG/T169-2016, a 50kg sandbag was used to continuously strike the wall 20 times without causing any loosening or collapse, demonstrating excellent impact resistance. In accordance with BS5234, a wall compression test was conducted at a height of 1.2 meters, where the load increased from zero to 2.0 KN/m. The deflection deformation was less than 1.0 mm, and after unloading, the wall returned to its original shape without any hazardous damage.07.Excellent durability and anti-aging performanceThe aerated concrete wall panels, made from lightweight aggregate concrete reinforced with steel, are identical to cast-in-place reinforced concrete frame structures. Consequently, their response to external climatic, temperature, and humidity changes is perfectly synchronized with the main structure, and they have the same service life.08.Autoclaved curing processAutoclaved aerated concrete wall panels undergo high-temperature and high-pressure curing processes in autoclaves, which accelerate the hydration reaction between cement and water during the curing process, resulting in stable concrete products. This method reduces the shrinkage reactions of the wall panels later on and shortens their production cycle, allowing us to promptly provide customers with the products they need based on their requirements. The economic practicality of aerated concrete wall panels01,Increase usable building areaSince 100mm foam cement wall panels can replace 150mm brick walls, and a 100mm thick wall panel is only two-thirds the thickness of a 150mm block wall, every 20 meters of wall adds 1 square meter of usable space. If a project uses 10,000 square meters of wall panels (with a floor height of 2.5 meters), the usable area increases by 200 square meters (2%), which is particularly attractive for residential and commercial properties.02,Reduce the loadA 100mm thick foam cement wall panel is equivalent to a 150mm thick aerated block wall, but its surface density is only 75 kg/m2; whereas, the surface density of a 150mm aerated concrete block wall is 138 kg/m2 (masonry 700 kg × 0.12 + double-sided plastering 1800 kg × 0.03). If a project uses 10,000 m2 of foam cement wall panels, the load can be reduced by 10,000 × (138 - 75) = 630,000 kg = 630 tons. If wall panels are used from the design phase, the foundation and main structure of the entire building can be significantly optimized, and the overall cost of the project can also be greatly reduced.03,Reduce construction wasteFoamed cement wall panels are lightweight precast concrete components with excellent verticality and flatness. After installation, there is no need for leveling or plastering. Additionally, the entire construction process uses dry methods, significantly reducing construction waste.04,Convenient for electrical and plumbing installation After the installation of foam cement wall panels, since the panels have a porous structure in the vertical direction, during the electrical and plumbing installation phase, workers only need to drill holes at the electrical box locations. Electrical conduits can run through the holes in the wall panels, eliminating the need for the tedious processes of drilling, backfilling, and others required for electrical and plumbing installation. This significantly accelerates the construction speed of electrical and plumbing work and reduces the labor intensity. Additionally, the wall panels can be pre-installed with electrical boxes, conduits, and other components according to customer requirements at the factory.05,No plastering, shorter construction period, reduced labor force Foamed cement wall panels are installed as whole pieces, resulting in extremely high construction speed, which is 3-5 times faster than brick walls. Additionally, after installing aerated concrete wall panels, there is no need for leveling and plastering, significantly reducing the construction period. This also greatly decreases labor requirements, and with the continuous rise in labor costs, the advantages of aerated concrete wall panels will become increasingly evident.PART 2 Production line components PART 3 Introduction to the Main Equipment Group moldHenan Zhihao House Equipment Co., Ltd. designs and produces a set of formwork for aerated concrete wall panel production lines with an automatic walking speed of 10 meters per minute. Each set of formwork can produce 24 wall panels (100mm thick) or 16 wall panels (200mm thick) per cycle and can be precisely positioned with auxiliary equipment. The formwork consists of a base frame, partition boards, end forms, movable bottom forms, and an electrical control system. Utilizing Manar's patented leak-proof slurry technology, it ensures high forming accuracy. The formwork can perform hydraulic opening/closing at fixed positions (end forms, side forms) and includes a mechanical walking mechanism, allowing wireless remote control. Blender and material distribution systemThe mixer consists of a mixing main unit, a weighing system, two levels of operating platforms, a discharge and distribution mechanism, powder tanks, and a screw conveying system, as well as an electrical control box and electrical system. It uses specialized mixing blades and high-speed stirring to ensure rapid mixing of the slurry. The mixing platform facilitates easy operation by personnel. Discharge is achieved through pneumatic butterfly valves, and material distribution is done via channels, ensuring uniform and controllable distribution. Top-forming machineThe upper molding cover plate placement system (robotic placement) consists of a walking mechanism, an upper pressing molding machine, a hydraulic system, and a control system, used for the upper pressing groove treatment after the mold cart is poured. The aluminum alloy mold is fixed together as a whole using brackets, and the upper molding machine's robotic arm grabs and places the aluminum alloy mold frame above the mold cart. After the cover plate is fully pressed, the robotic arm moves the aluminum alloy mold frame back and forth along the length of the mold cart to prevent air bubbles from appearing at the top of the product. The cover pressing and locking is manually locked, and the robotic arm descends to press tightly. The upper molding cleaning machine consists of cleaning devices, enclosures, and oil tanks, used to clean the residual slurry on the molding surface of the upper molding mold cart, using high-speed rolling brushes for cleaning. Integrated core extraction machineThe machine consists of a frame, positioning system, hydraulic system, core pulling and piercing system, and electrical control system. It employs Manar's patented technology (three technologies) to achieve high-tonnage core pulling (maximum pulling force up to 200 tons). It uses a hydraulic variable pump system to align with the set mold positioning, connect and disconnect with the core tube, and complete the core pulling and piercing functions. Open-close mold machineThe mold opening and closing machine consists of a base frame, a lifting frame, an end mold opening and closing mechanism, a side mold opening and closing mechanism, a hydraulic system, and an electrical system. It performs group mold opening and closing operations (end molds and side molds) at fixed positions with reliable and stable actions. pushing machineThe pusher machine consists of an outer frame, a cart, a push head, a motorized travel system, and a lower die retrieval system. During the process of pushing out the wall panel, the scraper fixed on the push head cleans the mold cavity. After the wall panel is flipped and packed, the lower die can be pulled back into the mold cavity by the lower die retrieval system located in front of the push head, achieving automatic repositioning of the lower die. flipper machineThe flipping machine consists of a base frame, a flipping frame, a bottom mold fixed seat, a hydraulic system, and an electrical system. This flipping machine can work with a pusher to return the bottom mold to its position; the flipping frame can perform a secondary flip, achieving a 180-degree rotation of the wall panel, which facilitates transportation and storage.Shuttle busZhihao's transfer vehicle achieves track workstation conversion for grouped mold setups (compared to single-purpose transfer vehicles, it easily accomplishes precise positioning between tracks, provides power to the molds, ensures mold positioning, and offers smoother movement). It uses variable frequency drive for walking, includes a hydraulic pump station, and achieves precise positioning with the track through the hydraulic system. Electrical control is done via wireless remote control.GraderThe Zhìhào leveling machine consists of a frame, a movable inner frame, a height-adjustable leveling scraper, a hydraulic system, an electrical system, and more. It is designed to work with assembled formwork sets, removing excess hardened slurry from the surface of these sets, thereby addressing issues of low manual efficiency and high labor intensity. Vibration deaeratorThe Zhìhàovibration Bubble Eliminator consists of a frame, a movable inner frame, a height-adjustable blade, a vibration unit, a guiding mechanism, a hydraulic system, and an electrical system. The blade moves along the guiding mechanism and is inserted into the mold cavity, simultaneously entering either 24 or 18 cavities at once. When the blade moves on the surface of the mold cavity, the vibration unit activates, driving the air bubbles to the interior of the wall panel, ensuring that the surface of the panel is free from noticeable air hole defects when it is removed.PART 4 Production line layout and processPART 5 Production line productivityProduction line power and production workshop area (for reference)Productivity(Ten thousand square meters/year)Man-hours(person/Class)Total power(kw)Operating power(kw)Factory floor area(m2) 100 15 400 140 3000 Henan Zhihao Industrial Co., Ltd. is a professional enterprise specializing in the research, design, and manufacturing of prefabricated formwork with over 20 years of history. As one of the leading companies in this field in China, the company provides extensive and professional services across multiple sectors, including bridge systems (such as cylindrical, box girder, and hanging basket formwork), highway systems (barrier piers, curbstone formwork), railway systems (T-beams, special-shaped piers), construction industry (wall panel equipment, prefabricated PC component production lines, assembly building molds), and large-scale cement prefabricated component building materials industry (double T-beams, trough slab roof molds). With profound expertise and rich practical experience in the development, design, and manufacturing of prefabricated formwork/molds, Henan Zhihao has always been at the forefront of the industry, delivering high-quality products and solutions to its customers.
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