Large WWC Wall Element Plant

Eltomation has in recent years developed a new production line for the manufacture of Prefab Large Wood Wool Cement Wall Elements.

The data below provides information on the following plant types as supplied by Eltomation:

A. Fully Automated Large WWC Wall Elements Production Line:
The Large Element Line allows the production of full-size homogeneous Wall Elements of up to 6 m length, 2,6 – 3 m height and 35 – 50 cm thickness. These Wall Elements provide a high thermal insulation, 6+ hours fire-rating, as well as a high heat storage capacity. These full-size wall elements allow the production of pre-fab housing units. This Full-size LE LINE is provided with a Double Forming Station to fill the large Forms on a continuous and homogenous basis in two layers.  The Large Element Production Line is amongst others equipped with an ELTOMATIC CVS-16 Rotating Wood Wool Machine, an advanced Cement Dosing System and a Continuous Mixer, which allows a production capacity of up to 9.000 kg/hour of fresh mixture. Furthermore, the LE Plant is provided with a 3 m wide Forming Station for the uniform filling of the Large Forms, as well as a conveying system for the automatic transfer of empty and full Forms. The Large Element Production Line includes a CNC Sawing and Milling Centre for the automatic cutting and milling of Large Elements to precise dimensions (including openings for window-frames, electrical wiring, etc.). Internal handling to and from storage areas can (optionally) be safely accomplished by an Automated Guided Vehicle (AGV). Ready Elements can be fully finished in the Plant, by already inserting window-frames and electrical conduits, as well as adding a base stucco/plaster, in order to reduce on-site labor during construction and as a result strongly reduce construction time.

B.  The so-called “Swivel Belt” Forming Line: This Large Element Forming Line is a smaller variant to the Fully-Automated LE Line. The “Swivel Belt” Line is designed with only one Forming Station, which fills individual large Forms one at a time. To allow the finishing of each layer and returning the Form to fill the second layer, some additional labour is required in comparison to the Fully Automated LE LINE. The Swivel Belt Line has a somewhat lower capacity and requires a lower investment.

For more pictures of the Large Element Plant, click here.

Plant Performance:

Based on a standard Element of 2,8 m x 6 m x 0,4 m (6,72 m³) and a density of 330 – 350 kg/m³, the Fully Automated LE Plant enables the production of up to approx. 22 standard Elements per shift.
Based on a combination of various sizes of one- and two-story houses (ranging from e.g. 72 – 160 m2 living space), the annual capacity of the line, based on 2-shift production (16 hours per day), allows for the production of Wall Elements for up to 1.000 houses per year.

The Swivel Belt Line will reach a capacity of close to 20 such Wall Elements per shift.

Element dimensions:

Height:2.600 – 3.000 mm
Thickness:300 – 500 mm
Length:up to 6.000 mm

Density:

The density of the Elements is approximately 330 – 350 kg/m3.

Raw Material and Raw Material Consumption:

The Raw Material Consumption per day, per each one (1) shift, based on the indicated production capacities is approx.:

Wood wool:20 ton
Cement:34 ton
Water:22 m³
Salt solution:1.4 ton

Wood wool is produced from small-diameter soft wood, mainly Pine (Spruce) or Poplar / Aspen as raw material. For example wood from forest thinning is suitable. The wood should be healthy and free from fungal attack or rot. Cement is common OPC Portland Cement, such as CEM I 52,5 N.

Labor requirements:

The following labor requirements apply, including labor for maintenance, warehousing, cleaning, etc.

Number of personnel per shift for the Fully Automated LE Line : 12-16
Number of personnel per shift for the “Swivel Belt” LE Line : 16-22
Plant management is to the discretion of Client

Power consumption:

Based on a full production capacity, the total installed electrical power and electrical power consumption for the Fully Automated LE Line are approx.:
Installed Electrical Power: approx. 1000 kVA
Electrical Power Consumption: approx. 750 kW

Building and land requirements:

An overall floor space of approximately 50 – 60 m x 180 m (9.000 – 10.800 m2) should be adequate for the Fully Automated LE Plant. This includes sufficient floor space for the Equipment and First and Second Setting Areas. Additional floor space may be required for storage of finished goods and for further processing such as pre-fab construction of houses (subject to local conditions). The overall building should have a clear height of approximately 7 metres minimum. Furthermore, for proper handling it is suggested to have an overhead crane above the storage area for the Elements, which requires a clear height of minimum 8 -10 m.

To allow for future expansions, it is suggested that approx. 3-5 HA land area is available.

Budget Pricing:

The budget pricing for the Eltomation scope of supply is as follows:

A. The Fully Automated Large Element Line: EUR 8.500.000,– to EUR 9.000.000,–, subject to final scope of delivery.

B. The “Swivel Belt” Forming Line: EUR 4.500.000,– to EUR 6.000.000,–, subject to final scope of delivery.

C. The Combined “Fully-Automated Forming Line” and “Swivel Belt” Forming Line (side by side with one combined Mixing Line): approx. 9.500.000,–, subject to final scope of delivery

This price includes engineering, project management, an estimate for CIP/CIF shipping charges as well as Installation Supervision and Commissioning charges. A detailed list of the items supplied by Eltomation is provided in our detailed System Proposal, which will be provided upon request.

Locally supplied items (such as fork lift trucks, cement silo’s, waste/dust recovery system, Moulds, etc.) are not included in the Eltomation Price and are to be sourced locally by Buyer. Eltomation will provide technical specifications for these locally sourced items.