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HOLLOW-CORE SLAB PRODUCTION

  • THK-Flow is the fastest and most reliable automatic hollow core casting machine on the market, which has all the equipments and functions for efficient production. Average casting speed varies from 1,2-2,5 m/min in dependence of slab height, aggregates, casting conditions and other factors.

  • THK-Flow casting machine uses a so-called shear-compaction technique. The machines feeding screws and moulding plates compacts the concrete mass into a precise and strong shape of hollow core slab. This technique is simple and of a compact construction. It combines the best features of the shear-compaction and slip-form techniques.

  • This is how we get good strength properties and casting results comparing to machinery using other methods. This series of machines consists of two parts-the power unit and the casting unit. The total height is 2550-2680 mm from the bed surface in dependence of the slab type.

  • THK-power unit:
    The power unit-includes control and automation devices and the concrete hopper. The power unit drives various interchangeable casting units for casting of 1200 mm wide and 150-500mm high hollow core slabs. The power unit also contains a belt driven concrete feeding unit for ensuring a steady flow of concrete mass to different casting units. Power unit is equipped with stepless control for all the working movements by means of frequency converters.

  • Power unit of THK-Flow is equipped with a display for control and monitoring of the machine's functions including e.g.
    -monitoring the load of all the working movements,
    -monitoring and adjustment the speeds of working movements,
    -three programmable buttons for the speeds of each movement,
    -alarm of overload and reset,
    -alarm of lack of lubrication,
    -signal of lack of concrete in the hopper

  • The operating system of the power unit controls automatically the concrete pressure during casting process (by braking or accelerating the machine) and also the quantity of concrete in the hopper by automatically starting and stopping its loading.

  • The operating system of power unit transmits a signal to concrete bucket for a new batch and stops casting machine in case the concrete is finished and starts again casting after loading of concrete. Power unit transmits a signal to THK-Gantry for synchronous drive during casting process.

  • Power unit stores operating parameters of all casting modules and restores respective parameters to each reconnected casting module.

  • Power unit's touch screen provides interface for the operator including e.g. the following functions:
    -setting of parameters
    -emergency stop,
    -start and stop,
    -selection of automatic or manual operation
    -opening and closing of service curtains.

  • All the functions of the machine can be controlled manually on the screen during maintenance.

  • Power unit specification:
    -Weight: 2500kg
    -Length: 5000mm
    -Width: 1750mm
    -Height: 2200mm
    -Connecting power: 60kW
    -Power supply: 3x100A / 400VAC 50Hz

  • Power unit includes:
    -Automatic and electric devices for machine operations.
    -Concrete hopper.
    -Belt driven concrete feeder.
    -Control link to THK-Gantry and THK-Cruiser.
    -Electrical and mechanical connection to casting unit.

  • Optional equipment:
    -Electrically operated cable drum.
    -GSM-Modem connection to control system.
    -Water tank for spraying the casting bed.

  • THK-casting unit:
    We manufacture a separate THK-Flow casting unit for every hollow slab thickness (150 mm, 200 mm, 265 mm, 320 mm, 320 mm heavy, 370 mm heavy, 400 mm and 500 mm).The change from one slab thickness to another takes about 5 minutes. This ensures flexible and uninterrupted production of hollow core slabs as well as lower production and operation costs.

  • THK-Flow casting unit has automatic electromechanical control system that allows the operator to select mechanically the pressure range for concrete compaction.

  • Casting unit specification:
    -Weight: 5400kg
    -Length: 4000mm
    -Width: 1650mm
    -Height: 1200mm

  • Casting unit includes:
    -Separate in different strokes moving leveling plates, to level the sides and upper surface of the hollow core slab.
    -Speeds of the leveling plates have stepless adjustment during casting process.
    -Adjustable angle of screw hopper and concrete feeding opening
    -The screw shafts are lubricated in oil bath
    -Mechanisms for horizontal movements are equipped with Metalflex system.
    -Feeding screws' speed can be adjusted stepless during casting process.
    -Automatic control system for compaction pressure on the top and bottom of the slab
    -Separate strand guides for upper and lower strands.
    -Automatic central lubrication for critical points.

  • The concrete used must be consistent, and the maximum aggregate size for 150mm slabs is 12 mm and for others 16 mm.

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