The Production Process of Prefabricated House Slabs

The production process of prefabricated house slabs varies depending on the technology used, with two common methods being foam-core prefabricated slabs and traditional hollow prefabricated slabs.

Production Process of Foam-Core Prefabricated Slabs

1. Mold Preparation: Workers first assemble steel plates into a large mold, tighten the screws, and then spray a release agent on the inner walls of the mold to facilitate the smooth removal of the prefabricated slab after it is formed.
2. Rebar Placement and Bottom Concrete Pouring: The first layer of rebar framework, known as distribution rebars, is laid inside the mold. Its function is to evenly distribute loads and enhance the overall structural integrity. Subsequently, approximately four centimeters of concrete is poured to provide a foundational load-bearing layer for the slab.
3. Foam Board Placement: A large foam board with a thickness of 15 centimeters is inserted. The foam boards are connected and secured with iron hooks to prevent displacement during subsequent operations. The foam board serves to provide thermal insulation, heat preservation, and reduce the weight of the prefabricated slab.
4. Upper Rebar and Steel Strand Placement: Another layer of rebar framework is laid on top of the foam board, and several high-tensile steel strands, known as load-bearing rebars, are threaded through. These steel strands can withstand significant tensile forces, enhancing the slab's flexural resistance.
5. Steel Strand Tensioning and Upper Concrete Pouring: Equipment is used to tension the steel strands to their ultimate strength, and they are fixed in place using the pre-tensioning method. Subsequently, a second layer of concrete is poured.
6. Vibration and Curing: A vibrating rod is used to vibrate the concrete, expelling air bubbles to prevent cracking and ensure its density. Afterward, the slab is lifted and sent to a basement for four hours of steam curing, allowing the concrete to harden rapidly and increase its strength.
7. Excess Rebar Cutting: After curing is complete, the steel strands are released, and an angle grinder is used to cut off the excess rebars, completing the production of the prefabricated slab.

Production Process of Traditional Hollow Prefabricated Slabs

1. Hollow Mold Production: First, wooden planks are nailed together to create a hollow mold, and rebars are placed inside the hollow section of the mold. The rebars enhance the load-bearing capacity of the prefabricated slab.
2. Concrete Pouring: The hollow section is filled with cement, which solidifies to form a structure with a certain strength.
3. Mold Removal: After the cement dries, the wooden planks are knocked off, leaving behind the prefabricated slab. The hollow structure of this type of slab achieves lightweighting by reducing the amount of non-load-bearing concrete, facilitating transportation and installation.