Energy efficiency in the production of concrete hollow core floor slabs

Energy efficiency in the construction industry is becoming increasingly important. The production of concrete hollow core floor slabs requires significant energy inputs, but modern technologies can significantly reduce them. Energy efficiency in the production of concrete hollow core floor slabs and optimization of production processes, implementation of innovative solutions and automation help to reduce energy consumption without loss of product quality.

Extrusion technology: a new level of energy efficiency

In the production of concrete hollow core slabs by extrusion, various methods are used to increase energy efficiency:

• Extrusion: this method allows the slabs to be formed by extruding the concrete mixture through a mold, ensuring high density and strength of the products. Extruders, such as the models presented by TDM, are equipped with independent screw drives and high-frequency vibrating rails, which contributes to the efficient compaction of the mixture and reduces energy consumption.

   

• Vibratory compaction: the use of high-frequency vibrating racks of a new design provides a uniform transmission of vibration to the entire surface, which contributes to the effective compaction of the concrete mixture and reduce energy costs.

One of the most energy-efficient methods of concrete slab production is extrusion molding. This method eliminates the need for classical formwork systems, which saves resources and speeds up the production process. Extruders for hollow core floor slabs work on the principle of layer-by-layer molding, providing high density and strength of products with minimal power consumption. Modern extruders are equipped with independent drives for screws and vibrating ribs. This allows for precise adjustment of operating parameters, reduces material overruns and energy losses. For example, TDM equipment is characterized by high productivity with minimal energy consumption, which makes it a profitable solution for reinforced concrete plants.

Rational use of thermal energy

The curing process of concrete slabs requires significant energy consumption for the curing process. However, modern technologies make it possible to significantly reduce this figure. The use of energy-efficient steam generators reduces fuel and electricity consumption, and the use of thermally insulated steaming chambers minimizes heat losses.

Additional savings are provided by the use of accelerated curing at low temperatures. This reduces dependence on heat treatment and reduces production costs.

Rational use of materials

Reducing material consumption without compromising product quality also contributes to improved energy efficiency in concrete slab production:

• Optimization of concrete mix composition: the introduction of high-performance plasticizing additives such as super plasticizers can reduce cement consumption by 20% without compromising the basic characteristics of concrete.
• Utilization of secondary resources: the use of recycled materials as aggregates or additives in concrete mixes helps to reduce the energy costs of extraction and processing of primary raw materials.

Automation and quality control

Another important aspect of energy-efficient production is the introduction of automated control systems. Programmable systems allow optimizing the processes of batching, mixing and placing concrete mixes. This not only reduces energy consumption, but also improves the quality of the final product. In addition, modern monitoring systems help to control humidity and temperature parameters, adjusting them in real time. This prevents unnecessary energy consumption and reduces the reject rate.

Reduction of energy consumption in the production of concrete slabs is possible due to the application of modern technologies such as extrusion molding, efficient curing process and process automation. A comprehensive approach to energy efficiency helps minimize production costs, improve product competitiveness and reduce environmental impact.