As you undertake your next construction project, a major consideration will be the suitability of the materials. Concrete products are popular alternatives to conventional products owing to their superior efficiency, durability, and visual appeal. Piling techniques are as old as the Roman Empire Era, but recent urbanization has been the biggest trigger to the growing popularity of concrete products.
The manufacturing processes for these products are fascinating, involving special machinery and equipment. As top concrete moulds manufacturersin China, we are here to expound on these processes briefly.
Read on for an insightful review of the manufacturing processes for centrifugal piles, centrifugal popes, and sewage pipes.
Before looking at the manufacturing process, it is important to define these products.
What is a centrifugal concrete pile?
A concrete pile is a structural foundation component commonly used to support a wide range of structures in offshore environments or anywhere else where the ground is too weak to support the structure’s weight. Examples of such structures are floating airports and bridges. There are many types of concrete piles including precast concrete piles, cast-in-place concrete piles, composite concrete piles, and enlarged tip files.
Centrifugal concrete piles are a form of precast concrete piles produced in the factory before being transported to the site. This manufacturing technique applies the centrifugal force concept via a spinning machine to distribute wet concrete evenly along the length of the mould. After the concrete has dried, the result is a compact product that is durable and strong.
What are centrifugal poles?
Centrifugal casting can similarly be applied to the manufacture of centrifugal poles. This fast spinning results in dense concrete poles with evenly distributed aggregates. Centrifugal poles have excellent surface finish and will last for ages. The dimensional accuracy and repeatability of the centrifugal poles are also admirable.
What are sewage pipes?
To add to the centrifugal piles and poles, there are sewage pipes made from concrete. Sewage concrete pipes typically comprise precast concrete with steel rebar reinforcement. They are available in a range of sizes from as small as 300mm to as large over 3500mm diameter.
You can custom manufacture these products to meet different customer and project requirements. Cast concrete pipes for sewerage are preferable for their environmental friendliness, design flexibility, non-flammability, and hydraulic performance.
Manufacturing Steps for Concrete Products
Manufacturing cast concrete products is systematic, yet it requires keen attention to detail. We cannot reiterate enough the need for advanced machinery and top-notch expertise in this process.
Save for customizations for the level of reinforcement, dimensions, and concrete mix properties, the manufacturing process for centrifugal piles, centrifugal poles, and sewage pipes is largely similar.
Here are the main steps:
1) Specify Design Parameters
The concrete mix should have a minimum compressive strength, say 4,000 PSI. Alongside the concrete mix, there are other design considerations for the manufacture of concrete products. Concrete thickness is one of them. A suitable pole, pile, or sewage pipe is strong enough for the loading conditions and thick enough to cover the reinforcement.
Talking of reinforcement, consider service conditions such as temperature. The reinforcement should be sufficient for the expected usage conditions. Ensure that the reinforcement has adhered to the applicable design and construction standards.
The designs for piles, poles, and sewage pipes differ owing to the different applications of each of these products. For instance, while sewage pipes are broader to accommodate a higher volume of sewerage, poles are slender to minimize weight.
2) Add Reinforcement
Reinforcement is essential for the overall strength of concrete products. Mesh panels and steel bars are the two most popular reinforcement materials for these products. These materials provide tensile strength for resistance against shearing forces such as vibrations while the concrete provides compressive strength.
So, add steel or any other reinforcement as specified in the design. Placement of the reinforcement matters as well as how well it secures within the mould. Place the reinforcement with space and distribution considerations to ensure that will eventually handle the anticipated loads.
Concrete moulds manufacturers consider space requirements for the concrete and reinforcement for the best outcome.
3) Spin the Contents
This is where you pour the wet concrete into the spinning mould. First, mix the concrete well and carefully pour it into the mould as it spins. The concrete mould is designed to accommodate enough concrete for the product.
Gradually increase the rotation speed on the spinning machine to generate the required centrifugal force for compact concrete free of air pockets.
Based on the specific design, the centrifugal machine may operate vertically or horizontally. Regardless of the orientation, the intense centrifugal force will force the material to distribute evenly on the walls. Eventually, the concrete will harden on the cavity walls and form the desired product – a centrifugal pile, centrifugal pole, or sewage pipe.
4) Cure the Product
Curing is a critical step in the concrete product manufacturing process because it helps develop longevity, water-tightness, and chemical resistance.
Initially, the product remains in the mould for several hours. You can then transfer it for further cooling, sometimes for weeks. You want to constantly check the ambient temperature and stick to the required curing time for the best results. Only when you are sure that the product has attained sufficient strength may you move to the next stage of the manufacturing process.
5) The Last Step - Finishing
Each concrete product has finishing specifications, which are important to follow. Generally, the product's surface should be smooth and devoid of air voids and honeycombed sections. Sanding or coating may be necessary if you want the pole, pile, or sewage pipe to have a specific surface texture.
How can we help with concrete products?
Understanding the manufacturing processes for precast concrete products is paramount for guaranteeing the longevity and reliability of centrifugal poles, piles, and sewage pipes. From the first step to finishing, every aspect of the process adds to the suitability of the final product to a project.
This guide has explored the intricacies of producing concrete moulds, but if you need consultation, our experienced team is here to help. We can provide state-of-the-art precast machinery for any type and capacity of construction project. Our concrete moulds are available in different shapes and sizes to suit project requirements.
Contact us to discuss the available options for your upcoming structural project.