Besides producing the usual type of wall panels slip forming technology also makes it possible to produce insulated wall panels - with or without exposed aggregates. While a normal wall panel (with or without exposed aggregates) can be manufactured in one production run on single machine, insulated elements require a second production run on an additional machine.
A customised topping machine has been developed for this purpose.
The production process is as follows:
- A standard slipformer (or a wall panel slipformer) lays the “bottom” structure in a first production run (= a pre-stressed hollow core slab of grey concrete)
- Insulation is applied manually – either PS (Poly-Styrene), PUR (Poly-URethane) or PIR (Poly-Isocyanurate) – thickness is typically 40, 60 or 80 mm (depending on the required insulation grade).
- On top of the insulation, a finishing layer is applied, consisting of grey (massive) concrete with a final topping of colourised concrete (which can be washed out to obtain exposed aggregates).
This customised machine runs over a normal slab (provided with an insulation layer) to make the topping.
The machine can be equipped with 2 concrete supply hoppers – the first one for grey concrete and the second one for colourised concrete. In this way a massive grey layer (on top of an existing slab with insulation) can be applied and, in the same run, a thin top layer a massive grey layer (on top of an existing slab with insulation) and, in the same run, a thin top layer. (The total depth of the layer is now +/- 60 mm).