The site selection and positioning process for constructing residential industrialized precast concrete (PC) factories generally follows these key steps: initially inputting project information, defining factory usage requirements, conducting preliminary planning for the new factory site, evaluating the feasibility of the planning scheme, refining the factory layout based on gathered feedback, coordinating with the customized factory building contractor to assess feasibility, obtaining senior management review, and finally confirming the factory location.
Image: 3D rendering of PC engineering
The standardized PC factory building typically features a four-span steel structure. It mainly includes:
- A multifunctional component production workshop, capable of manufacturing laminated panels as well as inner and outer wall panels;
- A special-shaped component production workshop designed for balcony panels, bay window panels, stairs, and steel reinforcement processing;
- A laboratory;
- Auxiliary storage areas for materials and finished products;
- Additional facilities such as boiler rooms and electrical distribution rooms;
- Office spaces and related amenities.
(1) Basic Factory Design
The multifunctional component production workshop is generally designed with dimensions of 100–150 meters in length and 24 meters in width. The crane lifting height should be at least 7–9 meters. The building uses a steel structure with ground hardening treatment, where the hardened layer is no less than 20 mm thick. The flooring at vibration system workstations and steam curing room workstations requires foundation treatment to support production processes.
The special-shaped component workshop is designed as a building 100–150 meters long and 2 × 24 meters wide. The crane lifting height must be at least 7 meters. The steel structure also incorporates a hardened floor layer. Production pedestals for balcony and staircase components require specialized floor treatment to accommodate their unique manufacturing needs.
A laboratory is established on the first floor of the office building to inspect and document key raw materials and production processes. This laboratory is equipped to automatically measure and record critical quality control parameters, such as steel bar and concrete strength, without manual intervention, ensuring traceability of all key data for each produced component.
The material storage area is divided into three zones for steel, sand and gravel, and finished product storage. Each finished product storage area is equipped with a 16-ton overhead crane for efficient handling. Supporting facilities, including boiler rooms and transformer rooms, are integrated within the factory premises to provide necessary gas, heating, and power supply.
(2) Production Capacity Design
The component production line operates on a 10-minute cycle, running two 12-hour shifts daily. The mechanical design, aligned with production organization and the number of circulating molds, supports continuous operation across two shifts and up to 300 working days annually. This setup allows daily production of up to 160 laminated or wall panels, translating to an annual output exceeding 48,000 pieces.
Balcony components are produced using pedestal methods, with 14 production pedestals arranged within the workshop. Operating two 12-hour shifts per day, this setup achieves a daily output of 28 units, resulting in an annual production capacity of approximately 8,400 pieces.
Stair components are also produced on pedestals, with 21 dedicated pedestals in the workshop. During two daily 12-hour shifts, each shift produces 12 small prefabricated structures, totaling 42 units per day. The annual output can reach up to approximately 12,600 stair components.
Must log in before commenting!
Sign Up