The Process

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

	Shaking Table or Dammed Inspection Station

Shaking, Consolidation & Curing
The steel table that contains the panels that have just received fresh concrete are now ready to be shaken in order to properly consolidate the concrete mixture. The entire steel table is shaken (not vibrated) at this station. First the table is shaken in the x-direction, then the y-direction, and finally in the z-direction. The z-direction is circular. These motions help create the smooth steel form (or textured formliner) finish.

Following consolidation procedures, the table is discharged on rollers to the inspection station located immediately in front of the kiln (curing room). At the inspection station, workers clean off any minor spillage and ensure alignment and check all other panel particulars for quality control purposes. After reviewing their entire checklist, the workers release the table to the curing room for its strength gain at optimum curing conditions.

The curing room accommodates the sixty (60) steel tables in a highly mechanized elevated rack storage structure. Five racks, 12 tables high reside inside the kiln allowing for the panels to gain their strength under highly controlled temperature and humidity levels. Heat and humidity can be added or taken out of this chamber to optimize the conditions for the hydration process. A typical precast panel can achieve 3000 psi compressive strength in about 9 hours. The first panel wythe is now complete. What follows next is the unique aspect of the double-wall process.