How to Make Prefabricated House Wall Panels

The production and construction of prefabricated house wall panels require selecting corresponding processes based on the type of wall panels (such as prefabricated concrete wall panels and prefabricated ALC wall panels). The core steps include mold preparation, material arrangement, pouring and forming, and on-site installation. The specific process is as follows:

I. Production and Construction of Prefabricated Concrete Wall Panels

1. Manufacturing Process (Taking Prefabricated Panels with Steel Strands as an Example)

• Mold Preparation: Workers use steel plates to make enclosures, fix the screws at the four corners, and then spray a release agent to prevent the concrete from adhering to the mold and ensure a smooth surface during demolding.
• Rebar Arrangement:
  • Erecting Distribution Bars: The rebars are hoisted from mid-air and positioned according to the internal space dimensions of the mold to form a grid-like framework.
  • Erecting Load-Bearing Bars: Steel strands are woven into load-bearing bars, which have higher tensile strength than ordinary deformed steel bars. Anchoring components with a diameter of 3 centimeters are installed on both sides to enhance connection stability.
• Concrete Pouring:
  • Using the Pre-tensioning Method: Equipment is used to pre-tension the steel strands to the designed strength before pouring concrete. After the concrete solidifies, the tension in the steel strands is maintained to improve the crack resistance of the wall panels.
  • Pouring Method: Concrete is automatically poured through an overhead track, reducing manual handling and labor intensity.

2. On-site Installation Steps

• Pre-construction Preparation: Utilize BIM technology to refine design drawings, coordinate with PC component manufacturers for production according to the schedule, and plan transportation routes.
• Installation Process:
  • Measuring and Setting Out: Verify the positions of connecting rebars, correct misaligned rebars, level with shims, and perform mortar bedding and compartmentalization.
  • Hoisting Interior Wall Panels: Hook and hoist to 1 meter above the ground, pause for 15 seconds to check for no detachment at the lifting points, then hoist to 1 meter above the working surface and decelerate for descent. Operators guide the wall down by hand, observe the alignment of connecting rebars with a mirror, and slowly descend to the shims before installing diagonal supports.
  • Calibration and Fixing: Use a level to check the verticality of the wall, unhook, and then recheck the deviation between the component and the installation position line.

II. Construction Process of Prefabricated ALC Wall Panels

1. Site Preparation: Clear the proposed installation site to ensure a flat and solid ground surface, preventing settlement after wall panel installation.
2. Installation Steps:

• Setting Out and Mortar Extrusion: After setting out, ensure the vertical joint width is approximately 5 millimeters and consistent from top to bottom. Check the mortar extrusion effect and repair any voids.
• Flatness Adjustment: Use a 2-meter level to check the wall surface flatness and make fine adjustments with a special pry bar to meet the standard.
• Mortar Filling: Clean the working surface at the bottom of the ALC panel, push and fill mortar until it overflows on the other side of the panel joint, and then smooth both sides to ensure a full joint.
• Post-installation Treatment: After the mortar reaches strength (about 7 days), remove the wooden wedges and repair and fill the positions with the same type of cement mortar; apply mortar on both sides of the installed panel end and fill half of the groove of the panel to be installed to enhance the connection.

III. Types of Prefabricated Wall Panels

• Interior Wall Panels: Include transverse wall panels, longitudinal wall panels (load-bearing), and partition wall panels (non-load-bearing), used for indoor space separation.
• Exterior Wall Panels: Include front exterior wall panels (self-supporting), gable panels, and eave panels, which bear the function of the building's external envelope.

Key Points: The production of prefabricated wall panels requires strict control over mold precision, rebar arrangement, and concrete pouring quality; during construction, BIM technology should be combined to optimize the process and ensure installation accuracy and structural safety.