PREFABRICATED WALLS MACHINE

PRODUCTION CAPACITY: up to 40 SQM / HOUR

BLOCKS USED: ground blocks with thickness from 10 to 50 cm.

DIMENSIONS OF THE WALLS: LUNG. MAX 9 MT / H MAX 3.25 MT

THICKNESS: MIN 10 CM - MAX 50 CM

 

The production process of the prefabricated clay walls starts with the automatic examination of the production process of the project carried out by the architect. The machine splits the walls into the modules of variable length dimension from 50 cm up to 9 mt, the wall height up to 3,2 - 3 mt for example from 10 cm up to 50 cm.

The production line uses the rectified clay hollow blocks or AAC blocks putting automatically a film of adhesive between one layer and the other.

The openings for the eventual windows or doors are carried out in an automatic way by the machine.

Eventual dimensional grinding of the wall in length or the dimensional grinding of the openings for doors and windows are done in the secondary step and always in an automatic way by the water cutting system at high pressure.

The final prefabricated wall is a monolithic structure, very strong even if it does not contain any steel reinforcement or cement and can be picked up and hooked from the top and it is sent to the building yard and it is positioned in such a way to become a building element.

The system is able to produce up to 45 m2/h in order to permit the construction of about 150 m2/hour of liveable surface

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STROJPANEL  KOMPLECT - RUSSIA

In collaboration with two important Austrian Companies Alpina Industriale has created a plant for the production of prefabricated walls in rectified brick blocks or AAC ( Aerated Autoclaved Concrete ) Blocks . With this system, prefabricated brick panels can be made with a maximum width of 9 meters and a maximum height of 3.25 meters in all possible thicknesses (the system built to date accepts variable thicknesses from 12 to 50 cm.). 

In the design of this system, ALPINA INDUSTRIALE started from two fundamental premises

  1. Using rectified hollow blocks or AAC blocks as the only element,
  2. giving to the architect maximum freedom of expression without imposing any modular constraints, being able to set the dimensions according to their needs

The operation of the machines is managed by a CAD / CAM system, which converts the designer's drawing to the wall construction program.

  1. Construction is fully automated in the diverse operating phases:
  2. removal of the brick blocks from the pallet - F
  3. handling and positioning of the blocks for the formation of the different layers of the wall - F
  4. programmed cut with circular saw that allows you to adapt the size of the wall to the exact measurements indicated by the designer, releasing it from the multiples of the basic module and allowing you to create openings such as doors, windows and also walls for flat roofs and pitched roofs;
  5. fixing the blocks for the formation of the wall: through a new and revolutionary patented glue that eliminates the use of mortar and iron;
  6. positioning of the rows of blocks for the formation of the wall using pliers.

There is no use of mortar, concrete or iron reinforcement; this gives the wall excellent thermal-acoustic insulation characteristics thanks to the substantial elimination of thermal bridges and good tensile and compressive strength making it a load-bearing wall with the possibility of building buildings up to 3-4 floors. However, it is also possible to combine the wall with a load-bearing structure with beams and pillars, making this system versatile and adaptable to traditional construction techniques.

Finally, the results of this type of prefabricated system are the same as those of a traditionally built wall but with some additional advantages:

  1. Reduction of building realization time
  2. Best quality / price ratio thanks to the reduction of labor costs
  3. Easy portability
  4. Excellent internal / external finishes
  5. Breathability
  6. High level of thermo-acoustic insulation
  7. Excellent fire resistance
  8. Improved lift thanks to the total elimination of mortar
  9. Living well-being
  10.  

Until now, the market has offered precast concrete systems. Thanks to this systems, the possibility of offering prefabricated houses in brick blocks makes its way onto the market, with the possibility of satisfying the demand for houses built with what has always been considered the most popular product in terms of thermal and acoustic insulation.

The plant is able to simultaneously treat four types of blocks. Normally it is possible to provide the rustic consisting of foundations, structure, curtain walls, roofing and, optionally, also the windows. The customer is responsible for the electrical connections and the thermo-sanitary services.

As shown in the graph, considerable savings are achieved which are obtained by reducing installation times. In fact, for the construction of a square meter of wall with the use of traditional blocks, 0.7 man hours are required, while with rectified blocks and the use of cement mortar this time is reduced to 0.55 man hours; with the revolutionary new glue, it even reaches only 0.35 hours / man, with prefabrication it reaches 0.15 hours / man.

It is interesting to note how the rectified block / glue combination makes the wall a monolithic block resistant even to tensile stresses even in the absence of steel, easy to lift and therefore to load and position. 

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