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SPIROLL PRECAST SERVICES LTD.

MANUAL FOR THE DESIGN OF A

SPIROLL HOLLOWCORE PLANT

Spiroll Precast Services Ltd.

Unit 2 Kingsway Industrial Park
Derby, DE22 3FP
United Kingdom
Tel: +44 (0)1332 365 131

Fax: +44 (0)1332 291 736

Web: www.spiroll.co.uk

Email: enquiries@spiroll.co.uk

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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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Table of Contents
The Spiroll Hollowcore System
The Spiroll Extrusion Process

Spiroll Hollowcore Slabs

Speed

Features of the Slab: -

Tests and Approvals

10

Spiroll Load Table

11

TermoDeck

Spiroll Factory
Start-up)

13

Design

(Typical
15

CEMENT SCREW CONVEYOR

Concrete Mix Design

27
27

Material Recommendations

27

Mix Proportion

28

Concrete Distribution

29

Gantry Crane

31

Overhead Crane

31

Forklift Truck

32

Readymix Truck

32

Concrete Distribution System 33

Scope of Plant Layout

15

Curing

Site Construction

16

Cutting the Slabs

37

16

Basic

Crosscuts

38

17

Basic Long/Rip Cuts

39

Basic Bed Requirements

18

Multi-Angle Cuts

40

Spiroll Bed Design

18

Secondary Cutting Station

42

Service Requirements
Production Beds

Abutments
Fixed Steel Posts

19

Lifting & Transporting the Slabs

43

19

Lifting (Stripping) Clamps

43

Hydraulic Detensioning System20

Multi-Stressing System

21

44

21

Prestressing & Equipment

46

22

Strand Dispensers

46

Stressing Equipment

47

Stressing Pump

48

Stressing Jack

48

21

Commissioning

Batching/Mixing

Transporting Slabs to the Stock

Yard
44

Preparing the Beds

Drainage

Production Processes

90o

36

22

Aggregate Bunker & Weighing

Belt Conveyor
22
Skip Hoist & Bucket Feeding

23

Stressing Grips

49

Main Chassis Superstructure

23

Digiforce Tension Meter

50

Single Shaft Axial Mixer

25

Basic Automation System

25

Computerised
Command
Control System (SCADA)
CEMENT SILO
EQUIPMENTS
SILO

&
26
26

OF

SILO-TOP FILTER

CEMENT
26
27

Fixing the Slabs

52

SlabLock Clamps

52

Fall Arrest Clamps

53

Edge Protection

54

Hollowcore Production Software 56

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The Spiroll Hollowcore System

The Spiroll Production System is an internationally proven, cost effective, economical method for the
production of Precast Hollowcore Concrete Slabs.

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.

The original Spiroll Producers founded the International Spiroll

Producers Association (ISPA) in 1969, which has since 1993 been
known as the International Prestressed Hollowcore Association
(IPHA) www.iphaweb.org.

There are currently in excess of 40 Spiroll Production Plants operating in over 20 Countries throughout the
world.

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The Spiroll Extrusion Process

The Spiroll Extruder is the heart of the production system. It was the Worlds first machine for producing
hollowcore slabs that did not require a separate driving force to move the machine along the Production
Bed. The same effort that feeds the concrete mix through the machine and forms it into the final precast
slab also provides the motivation to drive the extruder along the bed. This natural process propels the
Extruder along the Production Bed & allows the compacted concrete to reach the required density.

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

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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.

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Spiroll Hollowcore Slabs

In terms of selling the Spiroll Hollowcore Slabs into your local market you will see that the slab is such a
versatile precast element that it can be utilised in a wide range of applications and thus expand the
available markets.

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.

The high quality and excellent finishes of the slabs reduce

site work to an absolute minimum.

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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.

The Topping Machine is used to give special decorative

finishes to the hollowcore by using different aggregates
and colours on the soffits and tops of the slabs.

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.

Features of the Slab: -

Eye pleasing top and bottom surfaces.

Fire resistance (2-4 hours fire rating) depending on design

High density product

No strand slippage

Low cement content

Greater span/depth characteristics

Consistent camber

Greater span load characteristic

Close dimensional tolerances

Eliminates costly shoring during installation

All weather construction

Immediate working surface

Custom cut length to suit needs

Excellent sound barrier (due to hollows).

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Carpet direct top surface

Speedy erection, reducing interim financing

Maintenance free

Economical long line Production

Unlimited design possibilities, compatible with almost all building materials

Recommended for best use with TermoDeck heating & ventilation system

Flexibility in design & application

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).

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Tests and Approvals

Spiroll Hollowcore Slabs have World-Wide recognition & acceptance as a building element. Tests and
approvals are compiled in what now is Spiroll's Seven Volume Technical Manuals. Additional tests, which
have been done are as follows: -

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: -

15x120cm Hollowcore (No Topping)

20x120cm Hollowcore (No Topping)

25x120cm Hollowcore (No Topping)

32x120cm Hollowcore (No Topping)

40x120cm Hollowcore (No Topping)

47x90cm Hollowcore (No Topping)

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).

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Spiroll Load Table

LIVE LOADS (kN)

CLEAR SPAN (M)

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

--

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The Spiroll Load Tables show: -

Physical dimensions of the Spiroll hollowcore slab sections.

Strategic location (arrangement) of prestressing strands.

Yield (ultimate strength) of prestressing steel.

Superimposed load capacities for a given number of strand and span.

Governing design criteria for concrete strength and deflection 1imitations.

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.

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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 mass of the building, built using hollowcore, is used as

an energy store which creates an overall effect that damps
down fluctuations in temperature, resulting in reduced
energy needs for heating or cooling the air and for moving it
round the building.

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

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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.

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Spiroll Factory Design (Typical Start-up)

Scope of Plant Layout
The basis of the proposed production facility shall be two (2) 120 meters long Production Beds and 1.2
metres wide. This will provide an approximate output of 65,000m of slabs per annum based on an
average of two hundred fifty (250) working days per year.

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.

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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.

Roofed, insulated structure to cover production area.

Fully enclosed areas for parts storage and maintenance.

Service Requirements
-

Water Pressure

3.5 kg/cm

Electrical power

Industrial Input 3 phase 115 or 220 volt.

Covered Production Area

3,168m2

Stone and Sand Area

510m2

Batching Area

135m2

Stressing Cables Storage

432m2

Maintenance Area

44m2

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Parts Inventory Area

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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.

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Basic Bed Requirements

The following factors should be considered when constructing a bed for casting hollowcore: -

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.

Anchorage and weight To reduce transmission of vibration to the extruded product.

5.

Longitudinal movement To allow expansion and contraction of the steel bed with changes in
temperature.

6.

Foundation design To suit local ground conditions.

7.

Support and Fastening Methods To prevent longitudinal or vertical misalignment.

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.

Spiroll Bed Design

Spiroll Casting Beds are supplied in prefabricated in 10 meter sections. Each section contains Two Side
Member Channels running the complete length of the section and has Steel Cross Member Supports at
approximately 600mm intervals. A 8mm thick skin plate is welded to the Channels and in turn Chamfer
Rails welded to the skin plate. The surface of the skin plate will be grinded to the iron brightness.

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.

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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.

Fixed Steel Posts

The simplest & cheapest method is have fixed steel posts at both ends of the production bed. With this
method the strands are tensioned individually using a hydraulic Pump Unit & Stressing Jack.

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.

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Hydraulic Detensioning System

To get round the problem of Shock Detensioning Spiroll have developed a simple & cost effective
Hydraulic Detensioning System.

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.

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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.

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Production Processes
Batching/Mixing

Aggregate Bunker & Weighing Belt Conveyor

Aggregate Bunker:

1 unit

Volume :

45 m3

Number of Aggregate Parts:

3x15 m3

Discharge valves:

2 units / part

Pneumatic Piston:

6 units, PEMAKS

FRY Air Preparation Unit :

1 unit, REXROTH

Sand Vibrator:

2 unit, MVE 200/3,WAM

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.

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Weighing Belt Conveyor:

1 unit

Load Cell:

4 x 2000 kg

Dimensions:

1 unit, 800 x 9850 mm.

Rubber belt:

DERBY

Bearings:

SNA series with lubrication greaser

Drums:

Driving drum covered with10 mm rubber

Weighing bunker vibrators:

1 unit, MVE 200/3,WAM

Motor Gear Box:

7,5 kW,1500 rpm,i=12,GAMAK-DISSAN

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.

Skip Hoist & Bucket Feeding

Dry filling capacity:

750 lt.

Max. filling weight:

1100 kg

Motor:

7,5 kW, 1500 d/d , GAMAK

Speed of hoist up/down:

0,4 m/s

Main Chassis Superstructure

Plant chassis, which provides 4250 mm useful height, is produced from section - profile and sheet iron,
according to ISO9001 and all related DIN norms.

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.

Cement Weighing Hopper:

1 unit

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Weighing Capacity:

300 kg

Load Cell:

2 x 1000 kg

Pneumatic Valves:

V1-FS200S,WAM
Diameter 200 mm

Driver:

CP 101,WAM

Vibrator

Water Weighing Hopper:

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

1100 lt/min volumetric flow rate

5,5 kW motor power
550 lt depot volume
7,5 kg/cm2 operating pressure
Pipe and fittings materials

Water equipment
Piping installation on the plant
1 pneumatic valve, Valbia

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Note: Pressure tank and water piping installation up to the plant main chassis shall be maintained by the
customer.

Single Shaft Axial Mixer

-

Type:

MK 750/500

Mixer Capacity:

0.5 m3

Feeding Capacity:

750 lt.

Fresh Concrete Capacity

Compacted Concrete Capacity:

500 lt.

Motor-Reduction Gear Box Power:

18,5 kW , GAMAK - YILMAZ

Mixer Body & Side Body Inner Linings:

ST52-3 10 mm

Linings of mixing arms:

Ni-hard 20 mm

Water distributor

Pneumatic discharge door

Manual central lubrication system

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.

Basic Automation System

-

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.

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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.

Computerised Command & Control System (SCADA)

-

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.

Remote maintenance and servicing via Internet/intranet.

CEMENT SILO
-

Capacity:

50 ton / unit

Plate thickness:

5 6 mm

Filling pipe :

4 inches

Ladder, manhole, platform, and parapets are included.

EQUIPMENTS OF CEMENT SILO

Silo pressure safety valve:

WAM

Level indicators:

ILTC220,WAM (top and bottom)

Fluidisation nozzle :

6 units/Silo WAM

Mechanical valve:

V2FS250S,WAM

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FR Filter regulator

220 volt, solenoid valve

Pneumatic pipe installation

D E S I G N

SILO-TOP FILTER
-

Filter:

24 m2 JetPulse,WAM

Surface area:

24,5 m2

The number of filter cartridges:

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.

CEMENT SCREW CONVEYOR

-

Dimension:

193x7500mm,WAM (Universal Inlet)

Motor Power:

7,5 Kw

Capacity:

40 tons/hour

Concrete Mix Design

The Spiroll system uses an extremely dry concrete mix, typically a water/cement ratio of approximately of 0.20
to 0.30 (it may be necessary to allow approx. 0.05 additional for aggregate absorption).
The mix design will depend on the availability of local cement and aggregates and can be easily fined tuned to
suit local conditions. To reduce curing times and to allow double casting within a 24-hour period the cement
proportions can be increased.
A survey of customers suggests that the proportion of course to fine aggregates does vary to suit local
conditions.
Material Recommendations

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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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Normal Weight - "Average" Hardness (e.g. normal limestone)

Sand

44%

52%

44%

48%

Stone

40%

33%

36%

35%

Cement

16%

15%

20%

17%

Normal Weight - "Hard" (e.g. granitic)

Sand

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).

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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

Clear of floor space

CDS System

Automation

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Part of building
Cost of structural supports
Cost of Investment

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Gantry Crane

Overhead Crane

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D E S I G N

Forklift Truck

Readymix Truck

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Concrete Distribution System

The CDS is a smart crane concept, which was designed 10 years ago. It is a modular design based on
standard crane components that allows great freedom in lifting capacities and speeds. This System uses a
self-propelled Skip to receive concrete from the batching plant and deliver it into the Extruder hopper.

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.

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Features: -

Modular Design - flexible lifting capacities and speed of operation.

Ease of Service - are standard parts available worldwide.

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.

Bucket can be lowered to ground level

The hoisting-unit has a high safety level; the skip hangs in 4 separate ropes.

Guiding system that stops the skip hitting the beams

Advantages: -

The CDS will cut labour costs

The CDS will increase production capacity

Skip can be placed on an existing crane track

No additional crane track for a bullet bucket is necessary

The system is easy to program

The system is easy to maintain

The Skip is easy to clean on floor level

The CDS doesn't interfere with other machinery on the ground

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The CDS can be utilised to lift Production Machinery

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: -

Lifting capacity : max. 2m of concrete

Span : 15m

Bucket Hoisting speed : 0-10 m per min.

Crab travelling speed : 0-31.5 m per min.

Crane travelling speed : 0-100 m per min.

Lifting height : max. 6.5m

Skip capacity : 2m of concrete

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.

The system can be equipped with an anti-sway option.

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: -

Drawings of the layout of your production plant

Location of the Batching Plant

Number of the Casting Beds

Length of the Casting Beds

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Details on existing overhead cranes

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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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.

Cutting the Slabs

For reliable and consistent cutting of the slab: -

Allow a minimum power supply of 40 kilowatts.

Minimum water pressure of 50 to 60 psi at the saw.

Water facility to supply up to 36 litres per cut.

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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Basic 90o Crosscuts

The Spiroll Crosscut Saw is a basic and robust saw specifically designed for cutting 90 crosscuts along the
hollowcore concrete slabs.

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

Max Cutting Depth

320mm

Max Blade Size

900mm

Blade Motor Power

45kw

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Hydraulic Motor Power

9kw

Reels (Water/Electric)

0.5kw

Driving Speed

0 - 30 m/min

Cutting Time (20x120cm Slab)

90 seconds

Basic Long/Rip Cuts

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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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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

Max Cutting Depth

400mm

Max Blade Size

1100mm

Blade Motor Power

45kw

Hydraulic Motor Power

9kw

Reels (Water/Electric)

0.5kw

Driving Speed

0 - 30 m/min

Cutting Time (20x120cm Slab) 90 seconds

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Secondary Cutting Station

The Yard Saw provides a secondary cutting facility for long cuts and angle cuts to be carried out on the
hollow core slabs in the stock yard. This additional cutting facility enables a quicker turn around on the
casting beds.

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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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.

The Yard Saw has the following specifications: -

Length

5.45m

Width

1.80m

Height

3.21m

Weight

5100kgs

Max Cutting Depth

320mm

Max Blade Size

900mm

Blade Motor Power

45kw

Hydraulic Motor Power

9kw

Driving Speed

0 - 30 m/min

Cutting Time (20x120cm Slab) 90 seconds

Lifting & Transporting the Slabs

Lifting (Stripping) Clamps
The Spiroll Lifting Clamps are utilised to lift the product off the beds either by crane of forklift. They would
then be stacked ready for transfer away from the beds to the Stock Yard.

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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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.

Transporting Slabs to the Stock Yard

Options for transfer of product are: -

Forklift Truck Front Loader

Forklift Truck Side Loader

Stacker Lifters

Overhead Crane

Direct onto road trailers

Low trailer system

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).

Preparing the Beds

Once the hollowcore slabs have been cut to length & lifted away from the production beds, the beds then
need to be cleaned and oiled. The prestressing strands are then pulled the full length of the bed from the
strand dispensers, threaded through the abutments and the anchors fitted prior to stressing.

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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: -

- Cleans the Casting Bed

- Cleans the Bed Rails
- Pushes Debris off the Bed
- Sprays the Bed Oil/Release Agent
- Pulls the Prestressing Wires/Strands
- Lays the Slab Insulation Covers

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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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.

Prestressing & Equipment

Strand Dispensers

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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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.

Correct maintenance of the equipment and the training of personnel are

essential to ensure safe stressing.

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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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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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.

Advantages of the open grip include: -

Highly economical with few components

Ease of inspection during use
Ease of detensioning

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Ease of cleaning & maintenance

Spring Loaded Anchors (SLA's)

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.

Digiforce Tension Meter

The Digiforce is a portable, battery-powered Digital Tension Meter that measures the amount of
prestress load (kN) wire & strand.

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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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Fixing the Slabs

SlabLock Clamps
The SlabLock Clamps are a proven continental lifting and fixing system that has a 100% - 10-year safety
record. Most Clamps depend on gravity and lever action to give the required force to grip the slabs.
Knocking the slab or clamps could upset the grip - which may result in a potentially dangerous situation.

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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Fall Arrest Clamps

The Fall Arrest Clamp has been developed specifically for the site fixing of hollow core slabs & stairs. The
System is designed around a unique Automatic Safety Clamp that locks onto the hollowcore slab and has
a Quick Release Mechanism for ease of use.

Automatic Clamping Mechanism

Quick Release Lever
Simple to Use
Lightweight
Specific Application for fixing Hollowcore Slabs
Maintenance & Testing Support
Certified and CE approved by Lloyd's

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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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: -

Versatile Strapping System

Quick Release Lever
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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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Hollowcore Production Software

Spiroll FloorCAD is a hollowcore design & production software package that is fully integrated with
AutoCAD and WinFloor.
Control of logistics is vital to the success of hollowcore
manufacturing. It requires accurate and consistent control of the
design, production, marking, storage & site delivery. Spiroll
FloorCAD software has been designed and developed to provide
this support. It effectively ensures that the right product is made
at the right time to meet the individual project requirements.

Spiroll FloorCAD software effectively controls the factory. It saves

design office time, planning time, optimise materials & concrete
usage & facilitates identification and loading.

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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Spiroll FloorCAD allows you to control the manufacture of hollowcore slabs by the following functions: -

Drawing & Design:

Create & alter any profile shape & integrate with the AutoCAD layout.

Engineering drawings can be imported or redrawn.

Areas can be swapped until a suitable layout has been achieved.

One click design check on any slab.

Split slabs can inserted if required.

Configures slabs to suit the bearings and layouts.

Checks wire patterns, slab depths and toppings.

Prepares bending moment diagrams, shear force diagrams & calculations.

Calculations can be printed in Excel for design engineers.

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Production Control:

Issues production schedules of slabs for each project.

Plans production beds & optimises bed utilisation.

Prints bed production sheets.

Prints sketch cards for marking out & special work details.

Prints sticky labels for individual slab identification.

Storage & Despatch:

Prepares pick lists for loading.

Monitors loading sequence & weights.

Prevents vehicle overloading.

Controls site fixing progress.

Linked to accountancy package.

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Additional Features:

An unlimited number of software licences are permitted.

Annual design & software updates are provided at no additional cost.

Can be linked to a Bed Plotter.

We offer a full 60 day trial of the software with no obligation to buy.

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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