Professional Documents
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Hollowcore Plant Design Manual
Hollowcore Plant Design Manual
H O L L O W C O R E
P L A N T
D E S I G N
Web: www.spiroll.co.uk
Email: enquiries@spiroll.co.uk
S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Abstract
This document is designed to provide guidance and outline the main considerations in the initial planning of a
Spiroll Hollowcore plant. The information presented is based on 40 years of Spiroll experience.
To summarise the key points: -
The Plant must be planned with both the short term and long term annual square metres of
hollowcore slabs based on beds numbers and length. The normal bed length can vary from 60 to 150
metres Spiroll would recommend a length of 120 metres.
The Production Schedule must allow sufficient time for adequate curing of the hollowcore slabs
before the tension in the strand is released and slabs are cut and removed to allow daily turn round of
the beds.
The Factory Layout should include provision for immediate and future expansion of more
Production Beds so that the production can grow to meet market demand.
With a low cost start-up and access to one side of the beds, initially handling of product can be with a 5
tonne forklift. This system can be replaced by a gantry cranes, overhead cranes or travel lifts in the
future. Normal crane capacity would be 5 to 7.1/2 tonne.
Similarly for the first two beds installed concrete delivery can be by skip and forklift from a batching plant
or ready mix truck. This can be replaced by crane and skip or gantry/bullet skip distribution as
appropriate as the production volumes increase.
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H O L L O W C O R E
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Table of Contents
The Spiroll Hollowcore System
The Spiroll Extrusion Process
Speed
10
11
TermoDeck
Spiroll Factory
Start-up)
13
Design
(Typical
15
27
27
Material Recommendations
27
Mix Proportion
28
Concrete Distribution
29
Gantry Crane
31
Overhead Crane
31
Forklift Truck
32
Readymix Truck
32
15
Curing
Site Construction
16
37
16
Basic
Crosscuts
38
17
39
18
Multi-Angle Cuts
40
18
42
Service Requirements
Production Beds
Abutments
Fixed Steel Posts
19
43
19
43
21
44
21
46
22
Strand Dispensers
46
Stressing Equipment
47
Stressing Pump
48
Stressing Jack
48
21
Commissioning
Batching/Mixing
Drainage
Production Processes
90o
36
22
23
Stressing Grips
49
23
50
25
25
Computerised
Command
Control System (SCADA)
CEMENT SILO
EQUIPMENTS
SILO
&
26
26
OF
SILO-TOP FILTER
CEMENT
26
27
52
SlabLock Clamps
52
53
Edge Protection
54
S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Spiroll Hollowcore Slabs have good unsupported span characteristics with excellent load carrying
capacities and are used extensively for floors, roofs and walls in both commercial and, residential building
projects.
The Spiroll Corporation Ltd. originally developed the technology in Canada
in the 1960s and pioneered the production of hollowcore slabs using
long-line extrusion & high frequency vibration technology.
There are currently in excess of 40 Spiroll Production Plants operating in over 20 Countries throughout the
world.
S P I R O L L
H O L L O W C O R E
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D E S I G N
Due to the intense vibrations and pressure within the machine the concrete mix is
'plasticised' during the short time that it is passed through the Extruder which
allows it to be moulded and formed into the required section.
The formed slab then reverts to its 'dry' state and reaches such a high density that
it is possible to stand on the slab immediately after the extrusion process. After a
S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
period of natural or accelerated curing, the slabs are then cut to length, stripped from the casting bed and
transported to the storage area.
The casting beds are then cleaned, a release agent is applied and high tensile steel strands are located in
position for the automatic extrusion process to begin again. Normally the entire production takes place
over a 24-hour cycle.
Spiroll Extruders are by far the simplest hollowcore machine on the market in terms of their design & ease
of use. Once the machine has been commissioned & set-up to suit the Production Bed, it simply requires
the required mix to be put in the hopper and the machine to be started. There is no need to play around
with the concrete mix or adjust the Extruder once it starts running. The extruder only requires one man to
operate and is extremely easy to maintain. It is profitable because of the simplicity and reliability of the
overall design.
Spiroll Extruders are capable of producing hollow core slabs from depths of 150mm-470mm with widths
from 600mm-1800mm.
S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Few building materials available today offer the economy, flexibility and reliability of precast prestressed
concrete. The scope of applications is exceptional: -
Durability
Spiroll hollowcore slabs provide long-term performance in extremely harsh conditions that could destroy
lesser materials. It is extremely resilient to deterioration from the weather and the denser the slab the
higher the fire rating.
Speed
Hollowcore allows you the producer to have full control
over all the variables, which affect the durability, strength
and appearance of the slab.
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H O L L O W C O R E
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D E S I G N
Flexibility
Spiroll hollowcore slabs are not only a versatile flooring &
roofing application but when used in conjunction with the
Spiroll Topping Machine can also utilised for wall panels.
Economical
Spiroll hollow core slabs themselves are up to 30% lighter than the equivalent in-situ floor. Building
foundations can therefore be lighter as they are required to support less weight. Any supporting columns
and beams can also be significantly reduced. Longer spans and greater loads can also be utilised from the
Spiroll slabs.
No strand slippage
Consistent camber
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P L A N T
D E S I G N
Maintenance free
Recommended for best use with TermoDeck heating & ventilation system
There are a variety of uses for hollowcore with applications for floors, roofs and wall panels being the
most common. However, some of Spiroll's more innovative producers have found use for hollowcore in
such projects as parking decks, bridge deck (permanent forms), basement walls, retaining walls,
pedestrian bridges and parapet wall (air displacement).
S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Report on Structural Test on Spiroll Extruded Hollow Core Slabs, Report K68-05 Stockholm,
Sweden, August 1968.
Report on Test to Demonstrate the Adequacy of Floor or Roof Assemblies using Spiroll Panels
(By: S.B. Barnes and Associates).
Load Tables are available for the following depths of Spiroll Slabs: -
A comprehensive range of selections allows versatility and economy of materials by selecting the most suitable
slab for the load/span required. The table below gives a visual indication of which depth of slab to choose when
comparing the Live Loads (kN) against the Clear Span (m).
10
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3.0
4.0
4.5
6.5
9.0
11.5
16.5
0.0 - 3.0
3.0 - 3.5
3.5 - 4.0
4.0 - 4.5
15cm
4.5 - 5.0
5.0 - 5.5
5.5 - 6.0
6.0 -.6.5
6.5 - 7.0
20cm
7.0 - 7.5
7.5 - 8.0
8.0 - 8.5
8.5 - 9.0
25cm
9.0 - 9.5
9.5 - 10.0
10.0 - 10.5
30/
10.5 - 11.0
32cm
11.0 - 11.5
11.5 - 12.0
12.0 - 12.5
12.5 - 13.0
40cm
--
13.0 - 13.5
--
13.5 - 14.0
--
--
14.0 - 14.5
--
--
14.5 - 15.0
--
--
--
--
--
15.5 - 16.0
--
--
--
16.0 - 16.5
--
--
--
16.5 - 17.0
--
--
--
--
--
--
--
--
--
--
--
15.0 - 15.5
47cm
17.0 - 17.5
17.5 - 18.0
--
11
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D E S I G N
The concrete strength at 28 days is conservatively designated at 35 N/mm however, concrete strengths
of as high as f'c = 60 N/mm have been readily obtained by most Spiroll producers after the fairly dry
concrete has been extruded by the Spiroll Extruder.
12
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H O L L O W C O R E
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D E S I G N
TermoDeck
The TermoDeck System is a fan-assisted, heating/cooling
& ventilation system that uses the high thermal mass of
hollow core slabs through which warmed or cooled air is
distributed.
The supply air passes through the cores at low velocities, allowing prolonged contact between the air and
the slabs. This enables the slabs to behave as passive heat exchange elements that release heat to, or
absorb heat from, the air in the slabs.
If a building is well insulated, air tight and has heat recovery, the utilisation of the thermal mass of the
TermoDeck in combination, will produce a very efficient environmental control solution. As a result, a
13
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H O L L O W C O R E
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D E S I G N
building's requirements for heating and cooling systems, and related equipment will be less, and costs
significantly reduced.
A report on the Elizabeth Fry Building built using Spiroll Hollowcore Slabs and
TermoDeck (New Practice Final Report 106, 1998) by the UK Government's
Department of the Environment summarises its conclusions as follows: -
"Energy consumption is half that of a conventional building of this type. Use of the
building's thermal mass provides good levels of comfort. Occupant satisfaction
and productivity are high. Capital and maintenance costs are low".
TermoDeck is a proven and reliable system which has been installed over the last 25 years in more than
360 projects all over Europe and the Middle East. For further information on the TermoDeck system
please visit their website on www.termodeck.com.
14
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H O L L O W C O R E
P L A N T
D E S I G N
Provision shall be made for future expansion of an additional two (2) identical Beds. The system will
include two (2) Extruders; one (1) Saw and one (1) Pallet Cleaning Buggy.
This should be considered with a view to the future requirement for increased numbers of beds, the
handling of the product, the distribution of the concrete, the maintenance of the machines, drainage,
access, wiring of the beds and storage of the product.
There are advantages to site the mixer in the middle of the factory to minimize the travel time for the
concrete. Most factories however have end batching and have the appropriate size and speed of crane etc
for distribution of concrete.
15
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H O L L O W C O R E
P L A N T
D E S I G N
With an overhead crane the opportunity exists to extend the crane long travel beyond production
buildings. This enables it to be used for transfer of product to the yard and some for yard functions in the
future.
A Batching Plant providing for handling of two (2) aggregates and silo storage of cement, shall deliver
appropriate volumes of concrete to delivery buckets.
Transport of the Concrete Delivery Skip/Buckets to the Extruder shall be accomplished by Forklift Truck(s),
Overhead Cranes or other suitable methods.
Site Construction
Stressing Abutments and Production Bed foundations to be designed as per details provided by Spiroll
Precast Services Ltd and Soil Investigation Report provided by the customer.
Foundations for Batch Plant, electrical and mechanical distribution centre and cement silos.
Service Requirements
-
Water Pressure
3.5 kg/cm
Electrical power
3,168m2
510m2
Batching Area
135m2
432m2
Maintenance Area
44m2
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H O L L O W C O R E
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D E S I G N
50m2
Production Beds
The bed length is dictated by a number of factors, some of which have associated advantages and
disadvantages. These factors could be available space, production capacity, flexibility of production
volumes, strand patterns, bed utilisation, turn round time & off-cuts wastage.
Shorter Production Beds give easier coverage for curing, delivery and transport. They are more flexible for
scheduling of multiple machine sizes, but are not so productive. We would normally recommend a bed
length of 120 metres.
Water consumption for the casting (pallet water) is estimated to be between 250 and 500 litres per 100
square metres of bed.
17
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H O L L O W C O R E
P L A N T
D E S I G N
1.
Rigidity The plate thickness and the longitudinal/transverse support must be adequate to
prevent deformation of the casting surface by the weight and pressure of concrete.
2.
Dimensional tolerance To ensure that the strand is correctly position for consistent cover,
and that beds are not damaged during sawing, a straight line tolerance on the beds of 2mm
should be maintained over the bed length.
3.
Plate quality Good quality clean rolled plate must be selected to ensure a clean casting
surface with no curled ends.
4.
5.
Longitudinal movement To allow expansion and contraction of the steel bed with changes in
temperature.
6.
7.
8.
Pallet spacing - 2 metres is recommended although spacing can be down to 1.6 metres.
Construction techniques vary, but generally heavier construction gives more dimensional stability and
longer life.
Provision is made for six number 1 OD holes to allow for under bed heating pipes which creates an
independent radiator of each section to speed up the curing cycle. The inlet and outlet are connected to
a main supply and return that runs the full length of the bed.
18
S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
The sections are also supplied with Ground Fixing Plates and Resin Anchor Bolts supplied for fixing the
sections to the Concrete Base.
The assembly would consist of providing a concrete base for the bed. The 10m Sections are welded
together (after connecting the heating pipes together on site). Holes for fixing need to be drilled into the
ground and the Sections are secured with the Resin Anchor Bolts. After the installation the welds would
need to be grinded on each section and the Bolts can be screed over.
To reduce heat loss insulation sheets should be installed under the beds. Typically these would be
50/60mm foil backed sheets held in place by pressed metal angles or straps. On site the bed is filled with
concrete and covered with the layer of insulation, before turning and connecting together. If the beds are
filled with concrete prior to installation, the cross bars can be used to support the heating pipes and their
centres increased to 1 metre. If not filled the cross supports are drilled to support the heating pipes and
installed at 400mm centres.
Abutments
The capacity of the abutment design should take account of future requirements for deeper hollowcore
slabs as a small additional cost at the installation stage will save significant costs later (The stressing load
for a 400mm deep unit could be as high as 300 tonnes)
When preparing the ground works for the abutments provision should be made for future beds to
minimise costs.
However extra due care needs to be taken when cutting the strand or shock-detensioning to avoid
cracking & damaging the slabs. This can be done by releasing the tension at the edges first, preferable
with oxyacetylene torch. By pre-heating the strand with the torch before cutting the shock to the concrete
is reduced.
19
S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
The design of the abutment is based on two posts, which are cast on site into the concrete at an angle;
this allows the highest point of the assembly to be below the level of the beds. The Stress is transferred to
the posts by a yoke, which fits over the posts and is locked off, to allow the Hydraulic Detensioning
Assembly to be fitted & removed.
The beams for the yokes must be adequate for the bending moment and flexural strength. The cross
section of the welds must be adequate for the stressing loads. The welding is critical. A complete
assembly would include the posts, yoke and lock-off assembly. One assembly would be required for each
bed.
The design of the Hydraulic Assembly is based on releasing the lock-off and controlling the Detensioning
with hydraulic relief valves. The Cylinders are extended using a two-stage hand pump to maintain equal
displacement.
They have a 150 Ton Max Capacity. The Release Extension is 35mm. They also come complete with hoses
and a lifting point.
20
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H O L L O W C O R E
P L A N T
D E S I G N
Multi-Stressing System
Hydraulic Multi-Stressing is the most efficient and safest system. This method allows all the Strands to be
both stressed and detensioning all in one go.
Multi-Stressing significantly reduces the time it takes to stress with a Pump & Jack and eliminates the
possibility of bond slip or damage to the slabs caused by Shock Detensioning.
Drainage
Control of the water used during sawing, and maintaining a uniform level of water on the bed ahead of
the casting machine can be achieved more easily if the beds are installed with a fall of approximately 3 to
4mm per metre of bed run, over the length of the beds.
This will assist to maintain a uniform soffit finishes to the product and a clean well drained factory. Slurry
and waste material will be cleaned towards the wet which is normally also the mixer and wash down
end. The water should have free fall to a shallow catchments, which can be used to drain off excess water
and be cleared with a front loader.
Commissioning
Upon completion, by the owner, of all site preparations, foundations, building, provision of essential
services and compliance by owner with contract. Spiroll will provide sufficient technicians to install all
Machinery supplied by Spiroll.
Spiroll personnel will then proceed to commission the Spiroll equipment by demonstrating through a
complete production cycle, that all systems are operating satisfactorily.
21
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H O L L O W C O R E
P L A N T
D E S I G N
Production Processes
Batching/Mixing
1 unit
Volume :
45 m3
3x15 m3
Discharge valves:
2 units / part
Pneumatic Piston:
6 units, PEMAKS
1 unit, REXROTH
Sand Vibrator:
Aggregate bunker is designed and manufactured as per related DIN norms to operate under heavy
working conditions for long time. There exist 2 electro-pneumatically controlled discharge gates, which
provide easiness and choice in the discharge together with suitable elevation.
22
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H O L L O W C O R E
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D E S I G N
1 unit
Load Cell:
4 x 2000 kg
Dimensions:
Rubber belt:
DERBY
Bearings:
Drums:
Aggregate weighing belt conveyor, which has weighing capacity of net 3 tons (net 1,8 m3) with 2,5%
sensitivity, manufactured to operate without any problem under heavy working conditions with mechanical
separator, every kind of safety precautions, air pressure measuring device and etc. as per world
conditions. Aggregate is weighed by 4 units of load cells and weighing belt conveyor has all safety
switches like; rope controlled safety switch, emergency stop button.
750 lt.
1100 kg
Motor:
0,4 m/s
Below listed cement weighing and water weighing hoppers are mounted on a separate removable chassis
placed on the mixer chassis and equipment with ladder platform and parapets.
1 unit
23
S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Weighing Capacity:
300 kg
Load Cell:
2 x 1000 kg
Pneumatic Valves:
V1-FS200S,WAM
Diameter 200 mm
Driver:
CP 101,WAM
Vibrator
1 unit
Weighing Capacity:
120 kg
Load Cell:
1 x 1000 kg , ESIT
Pneumatic Valve:
V1-FS150T, WAM
Driver:
CP 101, WAM
Additive System:
1 unit
Capacity:
20 kg
Load Cell:
100 kg,EST
Pneumatic Valve:
1, Valbia
Pneumatic Equipment:
1 Set
Compressor:
TAMSAN
1 unit, MVE60/3,WAM
Water equipment
Piping installation on the plant
1 pneumatic valve, Valbia
24
S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Note: Pressure tank and water piping installation up to the plant main chassis shall be maintained by the
customer.
Type:
MK 750/500
Mixer Capacity:
0.5 m3
Feeding Capacity:
750 lt.
500 lt.
ST52-3 10 mm
Ni-hard 20 mm
Water distributor
625 lt.
Singe shaft mixers are easy to operate and long life mixers with very strong spiral shaped mixing arms,
compact structure and provide fast mixing, practical loading.
Command and control operations are done by PLC. At the maximum capacity high weighing
and dosage sensitivity can be achieved by advanced PLC programs and error control
algorithms.
Visualization and Control based on C7-635 system with integrated CPU S7-314C-2DP PLC,
SIMATIC HMI Panels.
SIEMENS Electrical Installation devices and sensors. Remote stations with distributed I/O
stations.
Real time simulation for operator training fast and safely without any lost material.
25
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D E S I G N
Increasing the production capacity and quality and more quality by using SIEMENS technology
and professional algorithms.
All kinds of parameter setup, receipt and calibration operations can be done on operators
panel screen; process, production and failure information can be taken.
Manuel and automatic operation can be done on illuminated mimic diagram. Voltage and
current values can be followed by digital indicators on the panel.
MCC and command panel is manufactured up to heavy operating conditions and has all kinds
of electrical protection.
All command and control operations, all kind of reporting, failure indications and etc are done
by PC Monitor and animation support with PC, printer, UPS and SCADA software.
Desired amount of receipt can be prepared, customer and truck information can be entered
and production information of at least past-one year can be shown.
All command and control operations, all kind of reporting, failure indications and etc are done
by PC and animation support with SIMATIC WinCC Flexible RT software.
CEMENT SILO
-
Capacity:
50 ton / unit
Plate thickness:
5 6 mm
Filling pipe :
4 inches
WAM
Level indicators:
Fluidisation nozzle :
6 units/Silo WAM
Mechanical valve:
V2FS250S,WAM
26
S P I R O L L
H O L L O W C O R E
P L A N T
FR Filter regulator
D E S I G N
SILO-TOP FILTER
-
Filter:
24 m2 JetPulse,WAM
Surface area:
24,5 m2
7 units
Air filtration flow of 2200-2500 Nm3/hr.
Filter has diameter of 800 mm, body made from 1 mm AISI304 material, cleaning system
Jet Pulse, electronically control.
Dimension:
Motor Power:
7,5 Kw
Capacity:
40 tons/hour
27
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H O L L O W C O R E
P L A N T
D E S I G N
Course Aggregates
10mm/14mm Aggregates (Max. Size 16mm for mechanical clearance).
Irregular shape is recommended. Extremes of very rounded or extremely angular respective are prone to
sagging and lower speeds or are difficult to compact.
Sand
Clean Zone 2 or equivalent.
Cement
Cement can be normal Portland cement or High Early strength cement as the contribute to workability and
benefit to rapid curing.
Water
This could range from 23 to 70 litres per cubic meter of mix depending on the moisture content and/or
degree of absorption of the aggregates.
Admix
Admixtures may be useful for workability or set control, but are not normally required.
Mix Proportion
The table below lists different Aggregate Types versus different Average Cement Contents & Proportions.
Type III
With
Type I
With
(High Early)
Additive
(Normal)
Additive
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H O L L O W C O R E
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D E S I G N
44%
52%
44%
48%
Stone
40%
33%
36%
35%
Cement
16%
15%
20%
17%
44%
43%
38%
Stone
39%
41%
45%
Cement
17%
16%
17%
Nil
Nil
Nil
Slag
Sand
46%
Stone
38%
Cement
16%
Nil
Expanded Clay/Shale
Sand
53%
Clay/Shale
20%
Cement
27%
55%
Nil
Nil
22%
23%
Concrete Distribution
While the Extruder is the heart of the Spiroll Hollowcore System, additional equipment is essential to
transport the concrete mix from the batching plant to the Extruder.
Delivery of the concrete must be carefully thought out so that the Extruder doesn't run out of mix and slow
down production. Several methods of concrete delivery can be used such as overhead cranes, fork lifts and also
more automated Concrete Distribution Systems (CDS).
29
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H O L L O W C O R E
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D E S I G N
To maintain continuity of supply of concrete to a Spiroll Extruder producing (as an example) a 200mm deep slab
would require 1m every 6/7 minutes.
The Extruder can be stopped between loads but it is preferable to maintain the continuity of the casting once
the line has been started. The permissible standing time before the machine has to be lifted clear of the curing
concrete would be established by trials but would not normally be between 5 and 10 minutes.
When delivering concrete the transfer between skips should be kept to a minimum to avoid segregation. The
skip should be bottom opening with a wide mouth (1m) to avoid trapping and segregation of the stone from
the fines.
Using an average extrusion speed of 1.2m/min and a Bed length of 120 metres, the casting time per bed would
be around 100 minutes. Transfer for lifting of the Extruder, setting-up, cleaning time etc. would add
approximately 15 minutes.
Consideration should be given to the systems available to distribute the concrete as follows.
METHOD
Forklift
BENEFITS
Low initial cost
Readily available
DISADVANTAGES
Floor space required
Reduced floor space
Gantry Crane
Danger of Legs
Overhead Crane
CDS System
Automation
30
Part of building
Cost of structural supports
Cost of Investment
S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Gantry Crane
Overhead Crane
31
S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Forklift Truck
Readymix Truck
32
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H O L L O W C O R E
P L A N T
D E S I G N
Operation: 1. The CDS is operated by a touch screen, which is mounted at ground level. The operator selects
the type of hollowcore that is to be produced.
2. The operator switches to auto mode (on the radio remote unit) and the crane will automatically
lift the skip and travel towards the filling station.
3. The hoisting unit automatically lowers the skip into the filling station and waits for the signal that
skip has been filled.
4. After the signal the skip will be automatically lifted and the crane and crab move toward the
Extruder.
5. As the crane and crab reach the Extruder the skip will automatically lower to the required level.
6. The operator must switch to manual operation and fill the casting machine by the remote control.
7. After the skip has been emptied the operator starts the automatic sequence again.
33
S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Features: -
All movements controlled by inverters - reducing wear on brakes, ropes and mechanical parts.
Touch-screen - operator can easily select the required program for automatic operations.
The hoisting-unit has a high safety level; the skip hangs in 4 separate ropes.
Advantages: -
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H O L L O W C O R E
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D E S I G N
Working with this system will improve the safety in the plant
Specifications: The standard electrically operated Automatic Concrete Distribution System is designed according to the
following specifications: -
Span : 15m
Optional Extras: -
An extra hoisting unit can be provided to adapt the system to lift the Extruder & other
production equipment.
Two extra hoisting units can also be provided to use the crane to lift the hollowcore slabs.
The crane can be installed with a modem, so that software can be serviced and changed
online.
If there are two or more cranes on the track an anti-collision system can be installed.
Depending on the existing facilities a filling station can be provided & installed.
If you have an existing factory and looking at the feasibility of adding the CDS to it then please ensure
you also include the following details: -
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Available Headroom
Curing
The application of heat into the cast slabs initiates and accelerates the curing of the concrete. The
Production Beds can be heated by either hot oil or water pipes running underneath the beds or by steam
curing.
Water is by far the most popular as it is reliable, cost effective, manageable and relatively cheap. Inlet
temperatures of 60 70c should be maintained with enough flow to maintain outlet temperatures at
around 25 35c.
To ensure good early strengths, heat should be applied during the casting operation and at the earliest
opportunity after casting the concrete should be covered with a plastic water retaining cover.
An optional Cover Trolley is available on the Bed Cleaner, which lays & picks-up the covers. This ensures
that the covers are used immediately behind the casting machine and reduce the time to apply and
remove the covers.
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Temperature monitoring can also be used to either spot check the temperature rise or with more sophisticated
systems to control the application of the heat.
The saw uses diamond tipped blades which can cost from 600 to 900 per blade. The target
cost of blades is around 30 pence per cut but up to 50 pence per cut is acceptable.
The estimated time for a cut is 1 to 2 minutes. With moving and positioning this gives a
cycle time of 4 to 5 minutes per cut.
Water can supplied to the saw using a hose Cable Reeler or a water supply provided at
quarter points down the bed.
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
The saw runs on the casting bed rails enabling it to travel over cut-outs in the slab. It can be adjusted relative to
the casting bed ensuring accurate 90 cuts and cutting depths. The hydraulic design allows ease of use and
better operational control. The saw comes complete with two hydraulic Cable Reelers for power & water.
The saw is designed to the following specifications: -
Length
3.58m
Width
1.81m
Height
2.46m
Weight
2300kgs
320mm
900mm
45kw
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
9kw
Reels (Water/Electric)
0.5kw
Driving Speed
0 - 30 m/min
90 seconds
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Multi-Angle Cuts
The Spiroll Multi-Angle Saw is designed to cut any required angle in the hollow core slab from 0-90. It also has
the capacity to cut long rips at any point along the precast concrete slab.
The saw requires an Operator to control the machine. The Operator has a clear unobstructed view of the hollow
core slabs and directs all movements through a hydraulic control system.
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
The saw a CCTV system so that the Operator can see in front of the electric reels where the view may be
restricted.
Optional extras include Laser Marking to ensure accurate cutting, Angular Measurement Tool, LED Display &
Glass Protection Screen.
Specifications: -
Length
6.20m
Width
1.90m
Height
3.30m
Weight
6000kgs
400mm
1100mm
45kw
9kw
Reels (Water/Electric)
0.5kw
Driving Speed
0 - 30 m/min
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
The beds can be stripped quickly and secondary cutting can be carried out without delaying the
production. Yard stock can also be cut to meet other demand
The Spiroll Yard Saw is essentially the same as the Multi-Angle Saw except the Operators Cabin is totally
enclosed and it doesnt have the hydraulic Cable Reelers for the water & electricity.
The Yard Saw has been in production since 1997 and is a tough and reliable saw. Because of its simple
design principles it has a very high productivity rate with minimal downtime.
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
The Yard Saw has the capacity to cut any angle from 0 - 90 degrees. The saw can cut at a rate of 1.5m to
2.0m/min in a slab of 150mm deep and has the capacity to cut long rips at any point on the slab.
The Yard Saw has a cabin for the Operator to work in which will be fitted with an internal light and 110v
plug. It comes complete with a laser and an Angular Measure Device is an optional extra.
Length
5.45m
Width
1.80m
Height
3.21m
Weight
5100kgs
320mm
900mm
45kw
9kw
Driving Speed
0 - 30 m/min
The Spiroll clamps are heavy duty and have high load ratings. They are designed with pivoting clamp
faces making it possible for the clamp faces to match the cross section regardless of any concrete growth.
Both erect and lifting clamps feature a quick engagement and release design for smooth continuous
workflow.
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
As the production volumes increase, in order to avoid single-piece movement from casting area to storage
the area, lifting equipment should be rated to lift and move to storage at least three to four pieces of
hollowcore.
Stacker Lifters
Overhead Crane
Bogie Trolleys
The production rate will call for movement of: approximately 75 square metres per hour (or approximately
6 to 8 pieces per hour assuming average lengths 8 to 10 metres).
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
To assist with these operations and increase productivity, the use of a combined Bed Cleaner, Bed Oiler
and Wire Puller is recommended. The Spiroll Bed Cleaner performs these functions: -
The Bed Cleaner is powered by a 4 Cylinder Deutz Diesel Engine. The various functions are all
hydraulically controlled by an Operator, who sits within the safety of the protective cabin.
The Bed Cleaner pushes the debris off the beds and it's 3 x rotating brushes clean both the pallet and the
rails.
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Mould Oil is sprayed on whilst travelling in the reverse direction. A light even coat is applied by the 6 x
Spray Nozzles to the pallet and rails in one pass at 45m/min.
The Bed Cleaner is also designed for simultaneous multi-strand pulling. The hydraulic strand carrier can
pull and deposit up to 10 x 12.5mn prestressing strands at a time. It also lifts and places them over and
beyond the stressing abutments.
This new design incorporates an optional Cover Trolley that is interchangeable and lays polythene covers
onto the hollowcore slabs in order to accelerate the curing time.
A floor area should be allowed for 5 or 6 strand dispensers with a configuration, which allows multi-pulling
of the strand, directly from the dispenser, along the bed by a bed cleaner or strand puller. A separate
storage area for strand should be available which is either covered or provision is made to support the
coils off the ground on timber batons and protection provided to prevent rusting.
A guide is normally fitted to the dispenser frame to direct the strand as it is pulled, and to guard against
coils being thrown out and becoming entangled of causing injury.
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Stressing Equipment
Spiroll is the UKs exclusive supplier of CCL Stressing Equipment. The combined strengths of the two
companies enable Spiroll to provide an unrivalled range of specialist Stressing products combined with a
unique after sales service.
All our Stressing Equipment is BSI Registered, which ensures piece of mind
for both purchasing a quality and reliable build & also for assurance in safety
standards during the stressing operation.
Particular attention is required to the condition and cleaning of the Stressing Grips. We can provide a full
range of stressing equipment should it be required in the future.
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Stressing Pump
The SR3000 Pump has been designed specifically for high speed - high volume stressing. The highly
modular design of this prestressing pump facilitates maintenance and servicing while its robust
construction provides excellent protection even in the toughest site conditions.
A push button remote is fitted as standard - allowing the Operator to be positioned safely out of the way
during stressing. The pump is also fully adaptable to different manufacturers jack models.
Optional Extras included a digital trip meter designed to provide up to 4 preset trip loads with the facility
to download and record data for quality control and statistical records.
Stressing Jack
The Stressomatic Jacks can pull from 3mm to 18mm wire/strand and are available and come in Short
Stroke (200mm Extension) & Long Stroke (500mm Extension) variants.
The Jacks come with Power Lock-off as standard. This unique feature allows the internal pulling wedge to
be pushed back against the stressing grip prior to the load being released. This ensures that when the
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
desired amount of prestress is reached there is no load loss and the concrete product will have the correct
amount of prestress.
The jack's high build specification means it is extremely robust and has a longer working life-span. A tool
kit is supplied as standard and includes everything to enable a wedge service to be carried out in a few
minutes.
Stressing Grips
The Open Grip is without doubt the most popular stressing grip. It comprises a wedge in a barrel and its
design enables the wedge position to be checked easily during use and allows unique accessibility during
detensioning.
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Spring Loaded Anchors (SLA's) provide correct positioning and are used at the non-stressing end of the
bed. The spring ensures that the wedges sit correctly in the barrel. This prevents them from being
dislodged by work at the prestressing end.
SLA's incorporate the same wedges as the open grip but have larger barrels and a spring mechanism. The
threaded cap anchors can also be joined together with a centre plug to make a double-ended joint.
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Very quick and easy to use, the Digiforce requires only two pieces of information to be keyed in; the
length of the member between its fixed points and its weight in grams per metre.
The wire or strand is then struck, causing it to resonate whilst the Digiforce is held in close proximity to
sample the frequency, within a few seconds the tension force is displayed on the screen.
It operates on the principle that when a tensioned member anchored between two points is struck it
vibrates at a frequency related to its tensile stress. The Digiforce detects the frequency of vibration
when held in close proximity to the member and computes it into a force value on the digital display.
The Digiforce has a data logger facility enabling test results to be saved and downloaded to a PC via an
RS232 serial port and is supplied in a robust carry case with a mallet, laminated look-up tables for the
weight of wires & strands.
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
The SlabLock erection clamps have a unique locking device which locks the jaws into any position,
ensuring that your lifting equipment is compliant with current lifting regulations and reducing the risks
associated with lifting and handling product on site.
The Slab Lock is available for various slab types and can be easily adjusted for various configurations.
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
For activities at a height over 2.5 metres a Personal Security Device is compulsory by EC norms if no other
protection is available.
This 'Active' Fall Arrest System is used when the preferred 'Passive' solution is not possible. In particular
when the hollowcore slab & staircases are being placed and the assembly crew is working at the
unguarded edge to receive and fit the elements.
The clamp is spring loaded allowing it to be placed with one hand only and ensuring that it always fits
neatly into the floor profile. If the safety line is loaded in any direction, it will immediately tighten up the
clamp grip and ensure that the clamp will not move from its allocated position.
The larger the load on the safety line, the greater the clamp grips. The clamp safety line is connected to a
certified and type approved harness.
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Edge Protection
The Edge Protection System that has been designed & developed to provide a temporary barrier for
Operators when fixing hollow core slabs and stairwells on site. This Edge Protection System offers a safe,
& practical solution to provide extra protection for Operators working on leading edges & around
stairwells.
This unique Edge Protection System incorporates an easy to use strapping system. The system has been
designed with a ratchet mechanism that tightens & locks it securely onto the hollowcore slabs. Scaffolding
or Fence Posts are then inserted to form the temporary barrier.
Features: -
S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Simple to Use
Lightweight
Flexible Application
Fitted prior to lifting/fixing
Certified and CE Approved
It is also possible for the Edge Protection System to be strapped onto the slabs prior to lifting and fixing
into place. This provides additional time-savings on site and also ensures that system is installed safely on
the ground.
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
The software provides the opportunity to layout the finished floor, designed to British, American &
European codes, and then translates it as a production plan back to the slab on the casting bed.
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Spiroll FloorCAD allows you to control the manufacture of hollowcore slabs by the following functions: -
Create & alter any profile shape & integrate with the AutoCAD layout.
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Production Control:
Prints sketch cards for marking out & special work details.
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S P I R O L L
H O L L O W C O R E
P L A N T
D E S I G N
Additional Features:
Spiroll FloorCAD is a cost effective package that gives total control from the first engineers drawings to
the final despatch and fixing of the product on site. The software package is rented out for a competitive
annual fee. There is no limit or extra charge on the number of users & upgrades are provide free of
charge.
Please feel free to contact Spiroll should you wish to receive further details or obtain a copy of FloorCAD
for trial purposes.
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