The Process

Layout Formliners, Steel Reinforcing, Window Bucks, Electrical Boxes Concrete Placement Shaking, Consolidation & Curing Flippjng & Flopping Installation of Insulation & Shipping About Our Plant

	long shot of the plant with tables in view

The Plant
The Naperville manufacturing plant producing the double-wall precast concrete product is an adaptation of European technology that has been used for close to twenty years throughout Europe. This is however, the very first plant of its type built here in North America. The layout of the equipment is that of a carousel plant-producing precast concrete panels for both walls and floors utilizing the unique double-wall process in a rotational manner. Robotics operates directly from CAD drawings to lay out panels to the exact building dimensions and specifications for each individual project. The highly efficient automated manufacturing process produces the highest quality wall and floor structural panels available in the building market today.

The plant's finished product is a precast insulated concrete sandwich panel, for both walls and floors. Panels are produced in 8-inch, 10-inch and 12-inch thickness. The typical panel consists of two layers of reinforced concrete which are held together with steel trusses, surrounding a layer of insulation. This is accomplished by preparing the first side (or wythe) in its entirety and then joining the first wythe and the second wythe in a unique and innovative manner. The double-wall method of manufacturing allows for both of the concrete surfaces to be form finished. Both the top and bottom of the floor panels are drywall smooth out of the plant, no additional toppings are needed. The interior of the walls are of the same quality smoothness, while the outside wall can be smooth or textured to any finish through the use of formliners during the fabrication process. The following section will run through the manufacturing steps for the production of the double-wall panels.

It is important to note that the double-wall process is achieved by producing each layer of concrete (outside and inside wythe) on a steel table. The following description will walk through the procedures for the first (Side A) wythe. The procedures for layout, concrete, etc. for the second (Side B) wythe are very similar. Any differences are noted.