The slab press UNI 2000 is the heart of any plant for the manufacture of concrete slabs. In addition, dosing and mixing plants, take-off devices with direct washing units and storage systems as well as machines and equipment for slab refinement and packaging are required. Masa can offer the complete know-how for the production of concrete slabs.
This is the decisive advantage for our customers: Planning, design, manufacture, assembly, commissioning, training, maintenance and continuous support during production – all from one supplier.
Would you like to learn more about the Masa concrete slab manufacturing process? Find out interactively step by step how a concrete slab is made from different raw materials.
Aggregate silos/dosing line
Quality right from the start – that is our philosophy. The use of high-end and well-thought-out dosing systems guarantee an optimum and efficient supply of aggregates (such as sand, cement, water, gravel, additives) to the concrete mixers.
The tried and tested Masa mixing plant concepts guarantee consistent and high-quality mixing results. One mixer for the face mix concrete and one mixer for the back mix concrete are required. "Face mix" means the visible surface of the slab-to-be, and "back mix" stands for the load-bearing invisible part of the slab.
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Slab press
The concrete slab production process is based on the compaction of concrete utilizing hydraulic pressing. In this procedure, two concrete layers are filled into the Masa slab press successively and compacted in a mould. The result is a two-layer slab.
The advantage of this method is that it gives concrete slab manufacturers great creative freedom. The visual appearance and structure of the visible slab face can - independent of the back mix layer - freely be varied.
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Take-off device
The take-off device serves as a link between the slab press UNI 2000 and the pallet transport plant. The fresh slabs are taken off the press by means of vacuum and/or grab devices and gently given over to carrying pallets that are provided by the pallet transport plant.
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Pallet transport plant
The Masa pallet transport plant ensures that the fresh slabs are transported from the press UNI 2000 to the stacking device gently and without loss of quality. For transport, self-stacking steel pallets are used.
As soon as a slab has been placed on the steel pallet, this is transported to the stacking device. Here, several steel pallets are compiled to a pallet stack. When the pre-defined stack height has been reached, the first pallet stack is moved forward and a second stack is piled up. Two pallet stacks together are then taken over by the pallet stack transfer device and transported into the hardening chambers.
Pallet stack transfer device
The stack transfer device consists of a lower car running on rails and an upper car with lifting device. When the stack transfer device has reached its exact position in front of the respective hardening chamber, the upper car moves the pallets into the selected chamber vibration-free. The storage pattern and the required drying period of the products depend on the chosen recipe.
When the hardening process is completed, the pallet stacks with the hardened products are again taken over by the stack transfer device and transported to the de-stacking device.
Curing chamber
The curing chamber is equipped with storage racks for the pallet stacks and sub-divided into single or double chambers or the open solution. The complete system should be encased, and there should be roller shutters in front of the chambers if the single or double chambers are used.
To optimize the curing process, different systems can be used:
- Air circulation systems
- Heating and steam systems
De-stacking device and return transport
The destacking device takes over the pallet stacks with the hardened slabs. The pallets are destacked so that the slabs can be taken off by a take-off device for further processing or packaging.
The empty steel pallets are then cleaned and oiled. After that, they are returned to the production cycle again.
Slab take-off carrier and transport system
The slab take-off carrier takes the hardened slabs and gives them over to a transport system which either gives the slabs over to a packaging plant directly or transports them to additional processing and refining stations for further enhancement.
The following refinements are possible:
- Calibrating
- Grinding
- Chamfering
- Shot-blasting
- Curling
- Impregnating
- Coating
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Packaging
A high-quality concrete slab requires sensitive handling. Masa offer complete and flexible packaging systems. These solutions comprise vertical and horizontal packaging systems that ensure that the surfaces and edges of the slabs are protected from damages during transport.
A cuber compiles several slabs to a package and gives this over to a package transport device. Transport pallets and packaging systems can be designed individually.
Package transport
The arranged slab packages are placed on transport pallets.
Masa can integrate various packaging systems into the area of the package transport that will safeguard the finished products. For later identification, the products can be marked by means of labelling systems.
Individual solutions are of course possible, please talk to us!
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Slab refinement
A Masa concrete slab making plant with additional types of equipment for slab refinement is the base for the manufacture of a wide range of products. This enables the slab manufacturer to react to market requirements with special patterns, designs, and product lines – or create new trends with own ideas.
The following refinements are possible:
- Calibrating
- Grinding
- Chamfering
- Washing
- Shot-blasting
- Curling
- Impregnating
- Coating
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It's a long way from raw materials through the mixture to the finished stone. Many plant components are involved in this process. Only if the system components are matched, can one be assured of a smooth process and economical operation of the block making plant.
It's a long way from raw materials over mixture to the finished (Kerb)stone. Masa Kerbstone presses were developed to fulfill among other criteria, the special requirements of the "British Standard" kerbstones. This "British Standard" is still a condition in countries of the Middle East and the UK.
The manufacturing of autoclaved aerated concrete products demands high standards for mixing and dosing of the aggregates, the control of the fermentation process and the control of each production step. Masa's aerated concrete installations are proven advanced technology processes, designed according to customers specific requirements. This approach allows complete solutions to ensure highly efficient, optimised processes resulting in consistent final product quality.
It's a long way from raw materials through the mixture to the finished sand lime bricks. Many plant components are involved in this process. Only if the system components are matched, can one be assured of a smooth process and economical operation of the sand lime brick production plant.
Masa plants and machines are installed and commissioned by our own experienced fitters. Masa relies on qualified personnel, trained in Germany.
The Masa Lifetime service extends far beyond the actual assembly and commissioning of a plant. Masa can rely on specific know-how and an industry experience of more than 110 years.
Do you need support with your machine? Masa Support scores in both quality and significantly improved accessibility. Whether "first aid" for technical problems, updates, functional expansions of your production plant or technical questions, the know-how provided by Masa Support covers a wide range of services.
One of the keys to increasing productivity and quality is continuous training of the machine and maintenance personnel.
Are you looking for your contact? The Masa Service team introduces itself.
