The Process

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

	Trussed Up Table Close Up

Formliners, Steel Reinforcing....
Once a table is received from the robotic layout area, plant workers take over the completion of tasks required to ready a panel for concrete placement. These tasks will include; cutting and placement of molded formliners onto the table within the specified locations, cutting and placement of reinforcing bars at the correct intervals in both the horizontal and vertical directions, selection and installation of shear trusses, placement of radiant floor heating tubes at predetermined locations within the floor slabs, construction and installation of wood window and door bucks at each opening called for in the plans, installation of conduit and boxes for electrical and communications systems that are within the panel limits, and the installation of foam blockouts at specified locations.

Removable formliners, when used, can give the finished concrete surface a variety of surface appearances and textures. They are a cost effective method to combine the strength of precast concrete with the surface beauty of other types of materials. Brick, wood, simulated limestone, and many other attractive surfaces can be produced with these formliners during the precasting operations. The reusable formliners are fastened directly to the steel table prior to the installation of any steel reinforcing. The concrete will eventually be placed onto the formliner, and when the formliner is later removed from the hardened concrete surface, the concrete face will resemble the exact appearance of the formliner. Stains and paints can be used to achieve the final look desired.

After formliner material is in place, (or if formliners are not used) the next step is the installation of the rebar. Reinforcing steel is placed per plan on the casting tables supported by plastic chairs to keep them in the proper location. The sizes and locations of the rebar are in accordance with the panel use, number of openings and design loads. Shear trusses are the next item installed in the panel. These triangular shear trusses are always placed in the first pour. They will span the two wythes and provide the wall (or floor) thickness.

Following the installation of the shear trusses (for the floor panels only) is the placement of the radiant floor heating tubes. The tubing comes in large coiled rolls so that each panel will have a continuous length of tubing with no joints within the panel area. The tubing is tied to the shear trusses at regular intervals to achieve uniform spacing.

Coiled spacers are installed at this time within the panels at predetermined locations. This spacers help maintain the correct wall (or floor) thickness and then later serve as the receptors for bracing inserts during the erection process on the job site. These spacers are glued down to the table. Lifting hooks are also installed at this time, so that they are cast within the concrete section.

When there is a door or window opening, a wood buck is fabricated and installed in order to "block out" the concrete form that area of the wall section. This buck can be left in the concrete panel and used as a nailer by the contractor. Vinyl or metal bucks can also easily be cast into the wall panel. Often times, basement windows are cast in right at the plant.

Electrical and telecommunication system boxes are glued down flush to the steel table in the specified locations at this time as well. Rigid conduit connects the boxes within the panel where appropriate and flexible conduit pigtails exit at the top and bottom of each panel. The electricians on-site will make all of the conduit home runs in the conventional manner from these stubs. Later, after doing all of the interior walls build-out, the electrician will pull all the wire throughout the entire building as normal.

Often times, foam blockouts are used to keep concrete material out of specified locations. Common areas in the floors include chase ways for heating ducts or plumbing runs. After concrete is poured during wall production, these foam areas can be easily removed by the various contractors on-site. Now that all of these operations are complete, the next step is placing concrete into the fully prepared panels.