Start precast floor production with a small investment

SEMI Floor technology is well-suited for any smaller-scale precasting need, anywhere in the world. With mechanized key processes and straightforward technology, the SEMI Floor production line produces high quality hollow-core, ribbed/half and solid slabs, and piles. The line has a low level of automation. All machines are low-noise, and they meet the EC Machine Directive requirements.

SEMI Floor can be a strategic tool: it is a cost-effective and easy way to set up and use a precast plant, also in emerging market areas with no previous factories. It can also be used to keep transport costs down by setting up a small plant near the site instead of delivering precast elements from a larger factory further away.

The production line provides a fast return on investment. It is easy to keep operation costs down as the production line saves remarkable amounts of raw material; when you save 100 kg/m3 of cement and have

30 % less scrap due to minimal strand slippage, the annual cost savings exceed 210,000 euro.

Affordable technology requires an innovative approach to R&D. “The idea was not to design more affordable separate machines but to combine them in a cost-efficient and intelligent way. This is a unique solution on the market”, says Jani Eilola, Product Director at Elematic.

The excellent slab quality of SEMI Floor is produced by a trio that forms the core of the production line: the Extruder P7, Sawpreparer S5, and Bed S5. SEMI Floor incorporates a budget-friendly solution of proven and efficient shear compaction technology that minimizes the use of concrete. The high compaction efficiency results in accurate geometry and a low number of rejected slabs.

“The 20 percent lower investment cost does not mean compromises in quality. Less automation and a simple design are combined with high quality standards. Precisely prefabricated modules make it all possible,” says Eilola. SEMI Floor provides excellent flexibility in production: the precast product to be manufactured can be changed easily and at low cost simply by changing the product modules.

The innovative sawpreparer combines three processes in one: sawing, cleaning and strand pulling. It also cuts the lifts in half compared to a separate saw and preparer combo. The sawpreparer is fully electronic and has four-wheel drive for cleaning and strand pulling. The excellent cleaning results give the end product a totally even surface. The need for maintenance decreases dramatically.

“Pulling the strands requires real strength. The 4WD sawpreparer takes care of business effortlessly, even up to 1,500 kilograms.”

The saw cuts reasonably sturdy slabs of up to 400 mm in thickness, even diagonally or at a horizontal angle of 90 degrees. It is also possible to cut slabs in half. There is no need for hydraulics or oil, it is 100 % electronically operated. “The machine keeps track of operating hours and the number of cuts. This data really matters in preventive maintenance”, Eilola says.

The even surface and the rigid steel structure of the bed guarantees the straightness of slabs. It is manufactured to strict tolerances.

“The new bed in the SEMI Floor production line has a highly optimized, simple and strong structure for good quality precasting”, Eilola describes. The installation is easy, no concrete filling is needed, and only a minimal amount of welding is required on site.