Elematic’s new machines for hollow core slab production

Elematic’s new Modifier E9-1200m is used for digging openings and recesses and drilling water holes on fresh concrete slabs on a hollow core production line.

The Modifier E9 features efficient concrete recycling. This is enabled by not using any water in the digging process, which means that concrete removed from openings can be recycled back to the extruder in the hollow-core slab production process. The Modifier thus forms an efficient working couple with the new Elematic Extruder E9.

Slab quality is ensured by mixing the used concrete gradually with fresh concrete as well as with a time limit; the used concrete will not be fed back to the process if it is older than a factory specific preset time value. Together the Modifier and Extruder are a perfect match increasing efficiency and sustainability of hollow-core slab production.

Elematic said that concrete consumption with Modifier E9 can be further reduced by an advanced digging mechanism that ensures minimum amount of concrete left on the bed.

The Modifier E9 also saves considerable time by eliminating the need for manual marking of cutting lines or making openings for lifting loop installations and through holes. The machine uses wireless technology to transfer bed plans to its FloorMES machine control system, and it can take the plans directly from BIM systems. Location information is acquired from the laser positioning system. The laser uses a mirror at the end of the bed to measure distance.

The Modifier E9 is fitted with a safety buffer on both ends, including light sensors that protect the area in the middle of buffers. There are also ultrasonic sensors, which enhance safety.

Extruder E9

The new Elematic Extruder E9 offers high casting speed, second-generation automatic compaction control and sophisticated bouncing prevention. Apart from the standard hollow core slab production, the new design of the machine also enables casting of a variety of precast slabs.

Equipped with an advanced touch-screen user interface, improved intelligence and a smart concrete recycling option, the Extruder E9 provides a new kind of modern user experience and significant material savings.

The machine delivers a high casting speed of up to 2.7 m/min - about 30% to 70% faster than its predecessors. “The high casting speed of our new Extruder translates into eight to 10 casted beds in the same amount of time that previously produced only six casted beds. This means even as many as 18 casted beds per day, which of course brings extremely high return on investment and naturally very profitable business for the precast producer,” explained Jani Eilola, product director for floor technologies at Elematic. “The remarkable speed is achieved with a new design of the extruding screws, optimised casting parameters and independent screw drives.

Similar to its predecessors, the Extruder E9 is based on shear compaction technology. Efficient compaction allows for minimum cement content in slabs, because the high density of concrete has an exponential effect on the slab strength.

Independent screw driving not only increases casting speed, but also enhances the versatility of the product range for the Extruder E9. Elematic said that for years, there has been a growing demand for casting different products fast with one machine and the new Extruder is designed to fulfil this need.

“A common example is casting narrow or split slabs. With the new Extruder, it is possible to choose from six different widths on a basic 1.2-m-wide bed. It brings considerable savings when narrow filler slabs can be casted instead of sawing them to correct measurements,” said Mr Eilola. The product range also covers solid slabs, wing slabs, piles and poles, and stadium slabs, among others.

Extruder E9 features a second-generation automatic compaction control system with the resistance of levelling beam as a new additional input parameter. Together with the independent use of the casting screws it guarantees a balanced casting process, as concrete is fed more evenly throughout the entire slab cross section. The casting process is monitored and controlled better, leading to improved slab quality.

The Extruder E9 is also equipped with an intelligent bouncing prevention system for stopping the pressure fluctuation during compaction from causing waves to the slab surface. Thus, slab surface will remain smooth and even. The Extruder E9 has a slow speed casting mode as well, reducing the need to stop casting when concrete supply to the machine is restricted. Less stops in the process results in better slab quality.

What’s more, the Extruder E9 comes with an option for a smart, environment-friendly recycling system that decreases concrete consumption and lowers production costs. Once the recycled concrete is transported back into the Extruder, the system slowly mixes it with the fresh concrete to ensure that the mix quality remains on the defined high level.

With this new launch, Elematic Extruder family now consists of three different models: S5, P7 and the new E9.

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