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Production line equipment to manufacture large panels with concrete brick machine by Saphia
Overall production line equipment is utilized in producing many large concrete panels with concrete brick machine, in an initial horizontal position, during each day of many operational days, with these panels preferably being later installed vertically with other like panels to form a sound barrier alongside a vehicle way.
Each concrete panel has its own integral pilasters at respective edges, in turn having respective tongue and groove edges; respective patterns and color accents on each side, with the pattern on the then top side being formed by using a rockable stamp subassembly, mounted on a cart; reinforcing throughout the panels, inclusive of the integral pilasters; lifting subassemblies; and anchoring subassemblies, adapted to be later mated with a receiving subassembly anchored in a concrete footing, located where the panel with other panels forms a sound barrier alongside vehicle ways. This, production line equipment is extended longitudinally, utilizing tracks to support several electrically powered vehicles, respectively referred to as tarp roller cart, back rail cart, mesh cart, rebar cart, screed cart, color spreader cart, and stamp cart.
Utilizing the knowledge known in the concrete industry, as exemplified in the patents referred to in the "Background", each of which in turn listed many references to earlier products and methods, and combining this knowledge with information concerning crane equipment, such as powered bridge cranes, other lifting equipment, color pigment distribution equipment, electrical power distribution equipment, hydraulic equipment, vehicle-like equipment, and imprinting equipment, this overall production line equipment and related methods of operations are provided to produce many large concrete sound barrier panels, in an initial horizontal position, during each day, of many operating days.
Each panel has its own integral pilasters at respective edges, in turn having respective tongue and groove edges; respective patterns and color accents on each side, with the pattern on the then top side being formed by using a rockable stamp subassembly mounted on a cart; reinforcing throughout the panels, inclusive of the integral pilasters; lifting subassemblies; and anchoring bolt and plate subassemblies extending from one of the pilasters, to be later mated with a receiving subassembly anchored in a concrete footing located where the panel is to be erected vertically and installed with other like panels. Together these panels create an attractive functional sound barrier alongside vehicle ways, such as freeways, roadways, and streets, thereby making nearby dwelling areas more pleasant to work in and/or to live in.
Although the panels are made specifically to meet detailed specifications, this overall production line equipment and related methods of operations are very easily adjusted to meet other specifications for other types of sound barriers, or for walls of buildings, or for other portions of other structures. Also this overall product line equipment, as illustrated, is readily changed to create panels of different heights, and to present different designs on all the respective sides. These convenient changes as to height and surface designs are prospectively necessary, because of the often varying specifications proposed, or demanded, by different communities, which are thereafter adopted by the designers of these sound barriers.
This overall production line equipment and associated methods of operations are designed to create a high quality concrete product while minimizing the personnel's efforts in handling form assembly parts, and minimizing the need for using independently operating lifting machinery, such as forklifts. To reach these objectives, form assemblies, presently numbering twenty, are arranged in a five hundred and twenty foot long production line having continuous tracks for electrical powered vehicles to run on. These vehicles are referred to as tarp roller cart, back rail cart, mesh cart, rebar cart, screed cart, color spreader cart, and stamp cart. Electrical power is distributed via a two hundred and forty volt continuous uninterrupted electric T-track power Supply System. Each cart has power outlets used in powering hand held electrical powered tools, and electrical circuits to operate components which are mounted on some of the respective carts.
Each form assembly, inclusive of the deck, forms, and track sections thereof, and a cured completed concrete panel is tiltable to an inclined position to facilitate the subsequent stripping of the concrete panel from the form assembly. Each form assembly includes a liner subassembly of plywood covered with a rubber or rubber like liner on which a specified design is created.
Therefore before stripping, tilt brackets are temporarily installed to receive the weight of the concrete brick machine, and thereafter during stripping, to rotate the concrete panel about a then removed center of rotation established by the tilt brackets Following this arc of rotation, the tilting concrete panel is kept well spaced and clear of the liner and the design thereon, avoiding any possibility of damaging the liner.
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