Advantages of Synchronous Vibration for Precast Concrete Manufacturing
Pouring strong concrete requires careful execution to minimize the risk of structural weaknesses and imperfections, and vibrating the concrete is one of the most crucial steps in the process.
When pouring precast concrete, it is important to vibrate the concrete evenly and consistently. Many traditional concrete vibration technologies will not produce optimal results, because the vibrators themselves are not synchronized. Nearly 40 years of experience in the industry has demonstrated to us time and again the advantages of synchronous vibration for precast concrete manufacturing.
How Vibrators Are Used in Precast Concrete Production
When you pour the concrete into the table initially, hundreds and even thousands of tiny air bubbles will form within the cast. Getting rid of these air pockets is practically a necessity because they can compromise the entire structure and reduce its reliability, and detract from the visual aesthetics of the end product.
External vibrators will vigorously shake the mold to release these air bubbles, and that function also serves another purpose — mixing. The creation of quality wet-cast concrete relies on intensive external vibration.
External precast concrete vibration, achieved through specialized equipment, will consolidate the mix’s contents more evenly throughout the mold to ensure strength and aesthetics of the finished product.
The Problem With Asynchronous Vibrators
When going through most available products, the standard external concrete vibrator is asynchronous. In fact, any electric vibrator, other than the brecon SL model is asynchronous. And what does that mean? When you mount multiple asynchronous vibrators on the form, the RPMs from vibrator to vibrator may not match. If you were to put ten vibrators in a row side by side, not one of the vibrators would match the others in terms of the RPMs that it is vibrating at.
Asynchronous vibrators are typically robust and quick to accelerate, which appeal to people who focus on completing the job as quickly as possible.
However, you need to use multiple vibrators on a mold to achieve even consolidation, and it’s difficult to match the RPMs of asynchronous vibrators up with each other. Unless monitored with extreme scrutiny, this discrepancy can result in uneven vibration, and an uneven internal structure for your concrete.
The Advantage of Synchronous Vibrators for Precast Concrete Fabrication
You can significantly reduce the issues encountered with asynchronous vibrators by replacing them with synchronous concrete vibrators. The latter models, including the Synchronous Vibrators, all remain within a single RPM of each other — producing precise, evenly distributed vibrations across the cast.
You can put ten synchronous vibrators in a row on a mold, and each one of those vibrators will be within 1 RPM of the other nine.
The advantages of synchronous vibrators include:
1. Less stress on the forms – synchronous vibrators don’t produce resonance vibration, which adds stress to the form.
2. A more consistent and even vibration, which creates concrete strength.
3. An aesthetically pleasing, better looking end product with a consistent product finish.
Supervisors can easily adjust the RPM of groups of vibrators with one press of a button, thus increasing overall convenience and consistency. When utilized correctly, synchronous vibrators can complete complex jobs more quickly than their asynchronous counterparts.
Vibrators can be arranged in production “zones” so that you can easily maintain a given set of vibrators at a given RPM, while another set of vibrators is set to a different RPM for a different application.
Overall, you’ll tackle wet-cast concrete vibration with little trouble when using synchronous wet-cast vibrators, which features a ruggedly constructed vibrator to withstand continued acceleration and on/off cycles over extended periods. You can adjust their pound force for added control over block forming, pipes, manholes, manhole spacers, walls and flat slab forming systems.
Synchronous vibrators are most advantageous when working with large wet-cast concrete tables.
Using these tools also increases reproducibility on the continued compaction process, thus improving overall product quality.
Trust Deca Vibrating Industries to Provide Your Vibrating Equipment
We provide experienced consultation and leading products for any client who requires external/internal concrete vibrators for precast concrete fabrication.