metre long by three metre high cellular
Gypcrete wall panel can be manufactured
every hour from a single casting table. Manufacturing installations that comprise
multiple tables will produce as many Gypcrete wall panels per hour
as there are tables in use. One installation can have
up to three casting tables.
A Gypcrete wall panel manufacturing plant comprises: -
- Plaster feed hoppers;
- Casting tables;
- Core-tables that insert and remove the plugs that form the cells in
the Gypcrete wall panel;
- A travelling gantry or crab assembly that mixes and dispenses onto
the casting tables, over which it passes, the plaster as well as the
chopped glass-fibre rovings;
- A Rapidryer oven used to cure the panels
The casting-table in each computer-controlled plant comprises a flat
steel epoxy-coated surface with raised operable sides to contain the
plaster when in the fluid state. Prior to the commencement of the
manufacturing process the casting table is first lightly greased.
Commencing from the start position the crab assembly moves over the
casting-table accurately dispensing the special plaster mix comprising
water, Rapidflow gypsum-plaster, and admixtures, over the entire table to
a depth of 13 millimetres.
This plaster layer is lightly screeded after which the travelling crab
assembly automatically chops and dispenses over the entire liquid-plaster
surface a predetermined quantity of chopped glass-fibre rovings to provide
reinforcement to the plaster. This layer of glass-fibre is then rolled
into the plaster to position it centrally within the 13 millimetre thick
In every 250 millimetre length of Gypcrete wall panel a 230 millimetre
X 94 millimetre cell is formed using greased removable plugs placed in the
direction parallel to the narrow dimension of the 12-metre panel.
Initially the core-table mechanism positions every alternative plug over
the plaster and glass-fibre layer on the casting table. The travelling
crab then dispenses a layer of chopped glass-fibre over these cores
automatically tamping it into position.
After completion of the tamping process the remainder of the cores are
positioned before the final quantity of plaster is dispensed onto the
casting table filling between the plugs and forming the top skin of the
panel. A final quantity of chopped glass-fibre is again automatically and
uniformly dispensed over the entire panel surface by the travelling crab.
The crab assembly then automatically returns to its cleaning and filling
station to be prepared for the production of the next Gypcrete wall
Using a mesh roller the surface of the Gypcrete wall panel is then
rolled to position this final layer of glass-fibre centrally within the
plaster top skin. Final screeding and smoothing of the cast but liquid
plaster is completed manually by two operators. From the commencement to
this process takes only 20 minutes after which the panel is left to cure
until the temperature and the consistency of the plaster allows final
Once the plaster has completed its initial set the core-table mechanism
advances and locks onto the core formers and slowly withdraws them from
the set panel and moves back and away from the casting-table to allow the
removal of the set Gypcrete wall panel.
To remove the panel from the casting-table all perimeter edges of the
table are swung open and two panel-supports are extended. The table is
then automatically tilted to approximately 150 off vertical with all of
the two tonne wet panel weight being taken on the bottom supports.
To this point, the entire process has taken 45 minutes.
Finally a multi-directional reach truck fitted with a transfer frame
removes the Gypcrete wall panel from the tilted casting-table and places
it in the Rapidryer oven line dryer for final curing prior to it being
stored in racks and ultimately cut to dimensions for installation on a
specific building project.
The elapsed time of the complete manufacturing process, including full
curing in the Rapidryer, is less than two hours.