4.10 Factory Production and Processing Technology for Prefabricated Components
4.10.1 Technical Content
Factory production and processing technology for prefabricated components involves using automated assembly lines, unit assembly lines, and long line pedestal production lines to manufacture standard-shaped prefabricated components, while also accommodating special-shaped components. Fixed table mold lines are employed to produce building prefabricated components, enabling batch production, processing, and centralized supply.
This technology encompasses the planning and design of prefabricated component factories, development of various production processes, design and processing of mold schemes, mechanized processing and forming of steel reinforcement products, mechanized forming of prefabricated components, energy-saving and curing technologies, as well as quality control techniques throughout production.
The production technology for non-prestressed concrete prefabricated components covers concrete technology, steel reinforcement methods, mold techniques, reserved and embedded element technology, pouring and forming processes, curing methods, and handling procedures including lifting, storage, and transportation. Typical components include truss steel reinforcement prefabricated panels, beam and column elements, and shear wall panel components.
For prestressed concrete prefabricated components, production technology also includes methods for pre-tensioned and post-tensioned bonded components. Beyond construction elements such as prestressed circular hole plates, double T-plates, roof beams, roof trusses, and roof panels, this technology extends to prefabricated bridge beams used in municipal and highway projects. Emphasis is placed on the production technology and quality control of prestressed components.
4.10.2 Technical Indicators
Scientific management combined with automated intelligent production in factories ensures and enhances quality. Dimensional accuracy for component appearances can reach ±2 mm, with concrete strength variation not exceeding 4.0 MPa standard deviation. The accuracy for reserved and embedded dimensions can reach ±1 mm, while the tolerance for protective layer thickness in prefabricated assembly is controlled within ±3 mm.
By controlling prestressing deviations and elongation values, the camber of prestressed components aligns with design requirements and industry standards. Component load-bearing capacity meets all design and specification criteria.
Geometric accuracy, concrete strength, embedded part precision, component performance, protective layer thickness, and prestressing requirements must comply with the design documents (including standard drawings) and relevant standards.
Additionally, production efficiency, cost control, energy consumption, environmental impact, and safety indicators of prefabricated component manufacturing are required to meet applicable regulations and standards.
4.10.3 Scope of Application
This technology is suitable for various types of reinforced concrete and prestressed concrete prefabricated components used in construction projects.
4.10.4 Engineering Examples
Notable projects utilizing this technology include:
- Beijing Vanke Jinyu Tixiang prefabricated wall panels and composite panels
- Beijing COFCO Vanke Changyang Peninsula prefabricated wall panels, stairs, composite panels, and balcony panels
- Shenyang Huisheng affordable housing prefabricated wall panels, composite panels, and stairs
- National Stadium (Bird’s Nest) viewing platform
- National Tennis Center prefabricated hanging panels
- Shenzhen Universiade Sports Center viewing platform
- Hangzhou Olympic Sports Center swimming pool prefabricated external wall panels and flooring
- Jinan Vanke Jinyu International prefabricated external wall panels and composite floor panels
- Changchun FAW Technology Center parking building prefabricated wall panels and double T panels
- Wuhan Qintai Culture and Art Center prefabricated plain concrete external wall panels
- Hebei Huailai Canaan Wine Factory prefabricated colored concrete external wall panels
- Power supply bureau production base factory prefabricated columns, roof panels, and crane beams
- Prefabricated T-beams for municipal roads, box girders, pipe segments, and pipe galleries
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