Fibrebond’s state of the art, PCI-certified manufacturing facility delivers consistent high quality products to our clients. Our automated concrete production facility allows for faster throughput time, tighter construction tolerances and increased volume.
Our production facility utilizes LEAN manufacturing principals to:
Quality inspections are performed during each phase of production to ensure customer specifications are met. Fibrebond can also serve as a warehousing source for customers’ valuable materials and equipment.
Fibrebond offers design development engineering services and logistical services, and has the capability to perform work as a general contractor. Below is a detailed, step-by-step look at Fibrebond’s manufacturing process.
Steel parts and foam for concrete panels are cut specific to each individual design. Simultaneously, inserts and pocket formers are prepared for layout in the casting bed.
Casting beds are set up according the size of the panel, including height and thickness.
All steel, foam, threaded inserts and welded wire fabric are installed in the casting bed, as required by the building design.
The computerized concrete batch plant sets a specific concrete mix for panels being produced. The batch plant monitors weather conditions, which results in more consistent mix designs, and gives Fibrebond the flexibility to cast any type of concrete mix.
The concrete mix is transported to the casting bed via the conflex bucket.
Concrete is poured into the casting bed using an advanced Skako panel casting system.
Bed mounted vibration and pencil vibration consolidate the mix to break free air and move the concrete to the bottom of the casting bed and prevent voids on the bottom of the panel.
The customer selected finish is applied to the top of the panel. A variety of finishes are available, including washed aggregate, stenciled brick, surface applied finishes, bare concrete and form liner finishes, such as siding, wood, etc.
The casting bed goes into the storage elevator to cure for 18 hours or until the panel reaches minimum handling strength. Once cured, panels are removed from the storage elevator and forms are released from the panel. Panels are then lifted out of the casting bed using an overhead crane and tilt table in most cases.
Panels move down the overhead monorail to be surface prepped for assembly. If the panel calls for a washed aggregate finish, it will pass through the wash station to expose aggregate and give the desired exterior finish.
Floor panels are placed on a rolling production cart and gasketed with a bead of urethane adhesive and a gasket strip. A short wall is then placed on the floor, plumb and square, and then bolted to floor panel. The adjoining wall is then gasketed to the end wall in the same fashion, the two panels are bolted together, and the process is repeated until an open top box is assembled.
Gasket material is placed on top of the walls and the roof is lowered on top of the walls. It is then bolted and moves into the completion process within the same day.
A quality check is performed on the inside of each building. Concrete panels are inspected for voids and defects. Once the inspection is complete, the building moves into carpentry where interior installation is performed on wall surfaces and ceilings.
At the same time, bolt holes are patched in the end walls and roof, and roofing is applied. Once complete, another quality check is performed and the building moves to mechanical.
In mechanical, buildings are prepared for AC systems and interior cable ladder. The building then moves to electrical where conduit boxes, panels and all other electrical equipment is installed. Wiring is then pulled and all connections are terminated to electrical equipment.
Another quality check is completed and systems are tested. If the building requires a generator, it is installed at this point. All circuits and alarms are tested again. All hardware, including doors, locks, closers and thresholds are installed.
Vinyl floor tile is then installed.
The building is then cleaned and a final inspection is completed. Buildings are “blue tagged,” an internal term indicating the building has been inspected by all departments. Items that ship with the building are packed, and the building is ready for shipment to the customer or to Fibrebond’s Installation Center for further installation of the customer’s specified equipment, such as batteries, racks, etc. Installation teams are also available to perform work in the field.
Buildings are loaded on trucks and trailers according to the weight and size of the building. Many loads require specialized hauling equipment and carried.
Buildings are transported to the customer’s site and offloaded with a crane of applicable size. Within days of the offload, the building can be on air.