Lightweight aggregate wall panel production line data
The products produced on the production linec-ement foam wall panels
Cement foam wall panels are lightweight wall boards made by quickly mixing cement, fly ash, water, additives, fiberglass mesh, and pre-formed foam in a specialized mixer, then forming them using a set mold. They are used for non-load-bearing partitions in industrial and civil building projects.
01.Reinforced steel frame
The steel-reinforced concrete structure, formed by combining rebar frameworks with lightweight aggregate concrete, enhances the bending resistance, crack resistance, and overall performance of the wall panels. This type of wall can be drilled or cut without affecting its strength, while also offering high hanging capacity (with single-point hanging strength exceeding 300 kg) and excellent impact resistance.
02.Strength and density
The strength and density of aerated concrete wall panels are well-balanced, with a strength of over 7 MPa and a density of around 1000 kg/m³. By maintaining a reasonable density, the wall panels achieve high strength, which is their standout feature. This high strength significantly enhances various properties of the wall panels, such as hanging capacity, impact resistance, and sound insulation.
03.Fire resistance and sound insulation performance
Due to the excellent fire-resistant properties of the steel-reinforced expanded clay concrete material, the wall panels meet or exceed national standard A-level fire resistance. Additionally, they do not produce any harmful gases when burning. The fire resistance limit of 100mm thick expanded clay concrete wall panels can reach over 2.5 hours. Expanded clay itself is an excellent thermal insulation and soundproofing material, and combined with the dense structure of concrete, it also provides excellent soundproofing performance. The 100mm thick expanded clay concrete wall panels can achieve a sound insulation level of 45 dB.
04.Excellent water and moisture resistance
Lightweight aggregate reinforced concrete panels, similar to regular concrete in internal structure, possess excellent waterproof and moisture-resistant properties. They can be used in areas such as kitchens, bathrooms, and basements without issues like moisture absorption leading to softening, efflorescence, deformation, or strength reduction. Therefore, the waterproof and moisture-resistant performance of these panels is significantly advantageous compared to other types of wall panels or blocks.
05.Excellent hanging performance
At any point on the aerated concrete wall panel, cabinets can be installed with anchor screws, they can also be hung or have marble mounted externally. The wall panel has a single-point suspension strength of 300 kg, and the anchoring components remain in place without loosening or falling off.
06.Excellent impact resistance and crush resistance
According to the testing method specified in the national standard JG/T169-2016, a 50kg sandbag was used to continuously strike the wall 20 times without causing any loosening or collapse, demonstrating excellent impact resistance. In accordance with BS5234, a wall compression test was conducted at a height of 1.2 meters, where the load increased from zero to 2.0 KN/m. The deflection deformation was less than 1.0 mm, and after unloading, the wall returned to its original shape without any hazardous damage.
07.Excellent durability and anti-aging performance
The aerated concrete wall panels, made from lightweight aggregate concrete reinforced with steel, are identical to cast-in-place reinforced concrete frame structures. Consequently, their response to external climatic, temperature, and humidity changes is perfectly synchronized with the main structure, and they have the same service life.
08.Autoclaved curing process
Autoclaved aerated concrete wall panels undergo high-temperature and high-pressure curing processes in autoclaves, which accelerate the hydration reaction between cement and water during the curing process, resulting in stable concrete products. This method reduces the shrinkage reactions of the wall panels later on and shortens their production cycle, allowing us to promptly provide customers with the products they need based on their requirements.
Serial Number
|
Project |
Indicators |
| Plate thickness 100mm |
Plate thickness 100mm |
| 1 |
Impact resistance/Next |
≥10 |
≥10 |
| 2 |
Bending failure load/multiplier of slab self-weight |
≥1.8 |
≥1.8 |
| 3 |
Compressive strength/MPa |
≥7.5 |
≥7.5 |
| 4 |
Softening coefficient |
≥0.8 |
≥0.8 |
| 5 |
Mass per unit area, kg/m² |
≤110 |
≤110 |
| 6 |
Moisture content |
≤6 |
≤6 |
| 7 |
Moisture content/% |
≤0.4 |
≤0.4 |
| 8 |
Suspension force/h |
≥1500 |
≥1500 |
| 9 |
Airborne sound insulation |
≥40 |
≥48 |
| 10 |
Fire resistance limit/h |
≥2 |
≥3 |
| Project |
Plate thickness(mm) |
| 90 |
120 |
150 |
| Impact resistance(Next) |
≥5 |
≥5 |
≥5 |
| Single-point suspension force(N) |
≥1000 |
≥1000 |
≥1000 |
| Bending failure load(Weight multiplier of the board) |
≥1.5 |
≥1.5 |
≥1 |
| Moisture shrinkage value(mm/m) |
≤0.6 |
≤0.6 |
≤0.6 |
| surface density(kg/m²) |
≤90 |
≤110 |
≤160 |
| Airborne sound insulation(dB) |
≥35 |
≥40 |
≥50 |
| Fire resistance limit(h) |
≥1 |
≥1 |
≥1 |
| Compressive strength(M Pa) |
≥3.5 |
≥3.5 |
≥5 |
| Thermal conductivity(W m².K) |
---- |
≤2.0 |
≤2.0 |
| Softening coefficient |
≥0.8 |
≥0.8 |
≥0.8 |
| Moisture content(%) |
≤12/10/8 |
| Annotation:Softening coefficient of gypsum board≥0.6 |
| Physical properties of lightweight panel boards |
The economic practicality of aerated concrete wall panels
01,Increase usable building area
Since 100mm concrete wall panels can replace 150mm brick walls, and 100mm thick panels are only 2/3 the thickness of 150mm block walls, every 20 meters of wall adds 1 square meter of usable space. If a project uses 10,000 square meters of wall panels (with a floor height of 2.5 meters), the usable area increases by 200 square meters (2%), which is particularly attractive for residential and commercial properties.
02,Reduce load
A 100mm thick aerated concrete wall panel is equivalent to a 150mm thick autoclaved aerated block wall, but its surface density is only 100 kg/m². In contrast, a 150mm thick autoclaved aerated concrete block wall has a surface density of 138 kg/m² (masonry 700 kg × 0.12 + double-sided plastering 1800 kg × 0.03). If a project uses 10,000 m² of aerated concrete wall panels, the load can be reduced by 10,000 × (138 - 100) = 380,000 kg = 380 tons. If wall panels are used from the design phase, the foundation and main structure of the entire building can be significantly optimized, and the overall cost of the project can also be greatly reduced.
03,Reduce construction waste
Lightweight concrete precast panels made of expanded clay aggregate have excellent verticality and flatness. After installation, no leveling or plastering is required. Additionally, the entire construction process uses dry methods, significantly reducing construction waste.
04,Convenient for electrical and plumbing installation
The installation of aerated concrete wall panels is complete. Due to their vertical porous structure, during the electrical and plumbing installation phase, workers only need to drill holes at the locations for electrical boxes. Electrical conduits can run through the holes in the wall panels, eliminating the need for the tedious processes of drilling, backfilling, and other labor-intensive tasks. This significantly accelerates the speed of electrical and plumbing construction and reduces manual labor intensity. Additionally, the wall panels can have electrical boxes and conduits pre-installed according to customer requirements within the factory.
05,No plastering, shorter construction period, reduced labor force
The installation of aerated concrete wall panels involves whole-piece assembly, resulting in extremely high construction speed, which is 3-5 times faster than brick walls. Additionally, after installation, there is no need for leveling and plastering, significantly shortening the construction period. This also greatly reduces labor requirements, and with the continuous rise in labor costs, the advantages of aerated concrete wall panels will become increasingly evident.
PART 2 Production line components
PART 3 Introduction to the Main Equipment
Group mold
Henan Zhihao House Equipment Co., Ltd. designs and produces a set of formwork for aerated concrete wall panel production lines with a self-propelled speed of 10 meters per minute. Each set can produce 12 wall panels (100mm thick) or 8 wall panels (200mm thick) in one cycle and can be precisely positioned with auxiliary equipment. The formwork consists of a base frame, partition boards, heating tubes (optional), end forms, movable bottom forms, and an electrical control system. Utilizing Manar's patented leak-proof slurry technology, it ensures high forming accuracy. The formwork can perform hydraulic opening/closing at fixed positions (end forms, side forms) and includes a mechanical walking mechanism, allowing wireless remote control.
fabric machine
The material distributor consists of an outer frame, a distribution hopper, a gate, a vibrator, a walking mechanism, a hydraulic system, and an electrical system. It uses spiral agitators and vibrators to assist with material discharge, ensuring that the slurry falls smoothly. The feed opening is wide, making it easy and convenient to load materials. Here, slurry splashing is severe, so sliding contact wires are used for the wiring to prevent wire damage and production disruptions.
Top-forming machine
In the traditional production process of wooden boards, a lot of manual labor is required for the top surface molding, and the molding effect is poor. Manar has developed an upper molding machine that uses a molding strip to press the top surface, turning the sixth surface into a mold cavity molding as well. The upper molding process includes an external frame, hydraulic system, an integrated upper molding frame, vibration motor, and hydraulic cylinder. During the downward pressing, vibration ensures that the upper molding strip is pressed down accurately.
Core puller
The machine consists of a frame, positioning system, hydraulic system, core pulling and piercing system, and electrical control system. It employs Manar's patented technology (three technologies) to achieve high-tonnage core pulling (maximum pulling force up to 300 tons). The hydraulic variable pump station system is used for aligning with grouped molds, connecting and disconnecting core tubes, and completing core pulling and piercing functions.
Open-close mold machine
The mold opening and closing machine consists of a base frame, a lifting frame, an end mold opening and closing mechanism, a side mold opening and closing mechanism, a hydraulic system, and an electrical system. It achieves reliable and stable hydraulic mold opening and closing (end mold and side mold) at fixed positions.
pushing machine
The pusher machine consists of an outer frame, a cart, a push head, a motorized travel system, and a lower die retrieval system. During the process of pushing out the wall panel, the scraper fixed on the push head cleans the mold cavity. After the wall panel is flipped and packed, the lower die can be pulled back into the mold cavity by the lower die retrieval system located in front of the push head, achieving automatic repositioning of the lower die.
flipper
The flipping machine consists of a base frame, a flipping frame, a bottom mold fixed seat, a hydraulic system, and an electrical system. This flipping machine can work with a pusher to return the bottom mold to its position; the flipping frame can perform a secondary flip, achieving a 180-degree rotation of the wall panel, which facilitates transportation and storage.
Shuttle bus
Zhihao's transfer vehicle achieves track workstation conversion for grouped mold setups (compared to single-purpose transfer vehicles, it easily accomplishes precise positioning between tracks, provides power to the molds, ensures mold positioning, and offers smoother movement). It uses variable frequency drive for walking, includes a hydraulic pump station, and achieves precise positioning with the track through the hydraulic system. Electrical control is done via wireless remote control.
PART 4 Production line layout and process
Plaster production line process flow diagram
Production line power and production workshop area (for reference)
| Productivity(Ten thousand square meters/year) |
Man-hours(person/Class) |
Total power(kw) |
Operating power(kw) |
Factory floor area(m²) |
| 100 |
23 |
400 |
140 |
6000 |
Henan Zhihao Industrial Co., Ltd. is a professional enterprise specializing in the research, design, and manufacturing of prefabricated formwork with over 20 years of history. As one of the leading companies in this field in China, the company provides extensive and professional services across multiple sectors, including bridge systems (such as cylindrical, box girder, and hanging basket formwork), highway systems (barrier piers, curbstone formwork), railway systems (T-beams, special-shaped piers), construction industry (wall panel equipment, prefabricated PC component production lines, assembly building molds), and large-scale cement prefabricated component building materials industry (double T-beams, trough slab roof molds). With profound expertise and rich practical experience in the development, design, and manufacturing of prefabricated formwork/molds, Henan Zhihao has always been at the forefront of the industry, delivering high-quality products and solutions to its customers.
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