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The Casting Process
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Omnia panels are 'wet-cast' into prepared steel moulds with stop-ends placed in accordance with a set of agreed dimensions to produce the exact shape of each panel.
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The stop-ends can be set at right angles to the edges, at straight angles, or even to a set of facets producing the semblance of curves. Whilst our skilled workers can produce almost any shape, they would prefer the odd right angle occasionally.
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Panel Widths
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Omnia wideslab panels are generally manfactured in standard widths of 2.40m, which are significantly wider than other precast flooring systems, allowing a much better erection rate, as each 'lift' can take up to 20m². Allowing 1 lift every 10mins, that equates to a coverage rate of 120m²/hour.
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Obviously shorter span panels will reduce this rate as well as other influences outside of our control.
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We also have a small manufacturing facility for panels 1.20m wide which we use for contracts that have a restriction on the size of the cranage. We would also suggest that all panels over 8.0m long be cast in 1.20m widths to reduce the individual dead weight, not just on site, but also at the point of casting.
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Whilst it would be very pleasant to provide standard panels, either 2.40 or 1.20m wide for all contracts, we are aware that virtually no structure divides easily into these dimensions, and so we provide non-standard widths of panels wherever necessary.
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Joints
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Each long edge on a standard panel is cast with a small chamfer. When two such joints are placed together, it creates a pleasant birdsmouth effect.
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The reason for the chamfer is to reduce the incidence of honeycombing during the casting process, and to eliminate any slight laying differential by actually highlighting the joint.
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Non-standard widths are cast against a longitudinal stop-end without the chamfer detail and as a non-standard edge is not as well defined as a standard chamfer we would always suggest that these edges are placed over the lines of supports.
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Panel Layout
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Our draughtsmen will work alongside the Architect and Structural Engineer to produce a panel layout that is aesthetically pleasing as well as structurally effective.
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