Gypsum wall panel production line data
The products produced on the production line-gypsum hollow wall panels
Gypsum hollow wall panels are made primarily from building gypsum, with optional additives or functional admixtures. The mixture is stirred with water to form a slurry, which is then cast, de-molded, and dried through various processes. To enhance the bending strength, fiberglass mesh is added to both sides of the panel during the forming process. These panels are used for non-load-bearing interior partition walls in buildings.
01.Environmental protection and waste utilization
Gypsum lightweight partition boards are made from industrial waste materials such as phosphogypsum and fly ash, without using clay or harmful substances to the human body, and they are non-radioactive, meeting the national requirements for environmentally friendly materials.
02.Excellent fire resistance
Due to the release of chemically combined water when gypsum is heated, its fire resistance limit can exceed 2 hours, and it does not emit toxic gases, with its non-combustibility meeting national Class A standards.
03.Low bulk density
Lightweight gypsum boards have only one-third the density of clay bricks and half that of hollow bricks, significantly reducing the structural load of buildings, decreasing foundation costs, and making transportation and construction easier, which lowers the total construction cost. They also enhance the earthquake resistance of buildings.
04.The wall has good earthquake resistance.
As it is an assembled construction, it features a three-in-one structure where panels connect to form a cohesive unit, providing strong impact resistance. It uses steel structure anchoring methods, resulting in high wall strength and low elastic modulus, which quickly absorbs impact energy, making it highly earthquake-resistant.
05.Excellent sound insulationperformanc performance
Gypsum boards are excellent building materials that provide both sound insulation and sound absorption, effectively blocking noise levels of 36 to 42 dB. Their sound insulation performance meets the national standards for residential sound insulation.
06.Lightweight insulation
Under identical conditions, gypsum lightweight partition boards weigh only 1/3 to 1/4 of brick walls. Additionally, due to the porous structure of gypsum boards, their thermal conductivity is 0.30 W/(m·K), which is superior to that of bricks at 0.43 W/(m·K) and concrete at 1.63 W/(m·K), providing excellent insulation performance.
Serial Number
|
Project |
Indicators |
| Plate thickness 100mm |
Plate thickness 200mm |
| 1 |
Impact resistance/Next |
≥5 |
≥5 |
| 2 |
Bending failure load/multiplier of slab self-weight |
≥1.5 |
≥1.5 |
| 3 |
Compressive strength/MPa |
≥3.5 |
≥3.5 |
| 4 |
Softening coefficient |
≥0.4 |
≥0.4 |
| 5 |
Mass per unit area, kg/m² |
≤80 |
≤80 |
| 6 |
Moisture content |
≤1 |
≤1 |
| 7 |
Moisture content/% |
≤0.4 |
≤0.4 |
| 8 |
Suspension force/h |
≥1000 |
≥1000 |
| 9 |
Airborne sound insulation |
≥40 |
≥48 |
| 10 |
Fire resistance limit/h |
≥3 |
≥3.5 |
| 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(MPa) |
≥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 gypsum soil wall panels
01,Increase the usable floor area of the building
Since 100mm gypsum wall panels can replace 150mm brick walls, and 100mm thick panels are only two-thirds the thickness of 150mm block walls, every 20 meters of wall increases usable space by 1 square meter. If a project uses 10,000 square meters of wall panels (with a floor height of 2.5 meters), it adds 200 square meters of usable area (an increase of 2%), which is particularly attractive for residential and commercial properties.
02,Reduce load
A 100mm thick gypsum wall panel is equivalent to a 150mm thick aerated block wall, but its surface density is only 80 kg/m². In contrast, a 150mm thick 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 lightweight concrete wall panels, the load can be reduced by 10,000 × (138 - 80) = 380,000 kg = 580 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
Gypsum wall panels are lightweight precast concrete components with excellent verticality and flatness. After installation, they do not require leveling or plastering. Additionally, the entire construction process uses dry methods, significantly reducing construction waste.
04,Simple construction
Compared to brick partition walls, gypsum partition panels are prefabricated and easy to transport. During on-site construction, there is no need to set up reinforcement bars, structural columns, lintels for doors and windows, or wet work. Gypsum wall panels can be nailed, sawed, and chiseled, making it convenient to pre-install water and electrical lines, install doors and windows, and handle joints. They are very easy to process. They can improve efficiency and reduce costs in terms of raw materials, labor, and construction time, and also generate less construction waste. After construction, due to the low shrinkage coefficient of gypsum wall panels, the risk of wall cracking is relatively small.
05,No plastering, shorter construction period, reduced labor force
Gypsum wall panels are installed as whole pieces, resulting in very high construction speed, which is 3-5 times faster than brick walls. Additionally, after installation, gypsum wall panels do not require leveling or plastering, significantly shortening the construction period. This also greatly reduces labor requirements, and with the continuous rise in labor costs, the advantages of gypsum wall panels will become increasingly evident.
PART 3 Introduction to the Main Equipment
Group mold
Henan Zhihao Housing Equipment Co., Ltd. , Ltd. designs and produces gypsum wall panel production line sets with self-propelled speed of 10 meters per minute. Each set can produce 12 wall panels (100mm thick) or 8 wall panels (200mm) per cycle and can be precisely positioned with auxiliary equipment. The set includes a base frame, partition boards, end molds, movable bottom edge molds, a walking system, and an electrical control system. Utilizing Manar's patented leak-proof technology ensures high forming precision; the partition boards are made of mirror-polished stainless steel, achieving mold cavity maintenance-free status, thus improving efficiency. The set allows for hydraulic opening/closing of the mold (end molds, side molds) at fixed workstations and includes a mechanical walking mechanism, enabling wireless remote control.
blender
The mixer consists of a mixing main unit, a weighing system, a platform, an unloading and distribution mechanism, powder tanks, and a screw conveying system, as well as an electrical control box and an electrical system. It uses specialized agitators and high-speed stirring to ensure rapid mixing of the slurry; the mixing platform facilitates easy operation by personnel. The unloading is done with pneumatic butterfly valves, and the material distribution is carried out through channels, achieving uniform and controllable distribution.
Top-forming machine
In response to the traditional plywood production process, which requires a lot of manual labor for top surface molding and results in poor molding effects, Manar has developed an upper molding machine. This machine uses a molding strip to press against the top molding surface, turning the sixth face into a mold cavity molding. The upper molding is composed of an external frame, hydraulic system, integrated upper molding frame, vibration motor, and cylinder. During the downward pressure, it vibrates to ensure that the upper molding strip presses down accurately.
Integrated core extraction machine
The machine consists of a frame, positioning system, hydraulic system, core pulling and piercing system, and electrical control system. It uses Manar's patented technology (three technologies) to achieve high-tonnage core pulling (maximum pulling force up to 200 tons). It employs a hydraulic variable pump system to align with the set mold positioning, connect and disconnect with the core tube, and complete the core pulling and piercing functions.
pusher 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 in front of the push head, achieving automatic repositioning of the lower die.
flipper machine
The flipping machine consists of a base frame, a flipping frame, a bottom mold fixed seat, a hydraulic system, an electrical system, etc. 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 position conversion for grouped mold setups (compared to single transfer functions, it easily achieves precise positioning between tracks, provides power to the molds, ensures mold positioning, and offers smoother movement). It uses variable frequency 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 |
10 |
230 |
80 |
1500 |
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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