All of the products produced by Oran Pre-Cast are manufactured in the one facility, located just off the M6 motorway, in Oranmore. The facility extends over forty acres and is located adjacent to our administrative and design office.
The plant has a number of specialist production units for our various products. All of these individual units are serviced by centralised on-site steel fabrication and reinforcement bending workshops, along with 2 concrete batching plants. This ensures that our Quality Control team can monitor all aspects of production process to ensure that the highest standards are maintained.
Once issued for production all products are logged in a product management system. Each product is labelled with a barcoded sticker that allows it to be tracked through the entire production process. An online database can be queried to show the current status and position of any product.
There are 3 main production units within the plant, each catering for a different manufacturing technique or process. The products manufactured in each can be grouped as follows:
Twinwall and lattice floor,
Prestressed floor and
Beams, columns and stairs.
Twinwall and Lattice Floor
Twinwall and lattice floor are made in a fully automated carousel production plant. The plant, commissioned in 2004, was the first of its kind in the British Isles. On a single shift rotation it has a production capacity of 3,500m2 per week. The plant can operate in a double shift pattern to increase capacity as required.
The full production cycle for twinwall takes approximately 48hours. Beginning at a cleaning station, where the production table is cleaned and polished, the table passes through a series of workstations before reaching a curing chamber. These include a plotting station, where a robotic arm plots the panel outline from the production cad drawing, and a reinforcement station, where the reinforcement is cut and positioned robotically. Due to the highly automated nature of the system nonstandard panel shapes can easily be accommodated.
See our video which details the manufacturing process for a typical twin wall panel manufactured in our state of the art facility - Oran Precast Twin Wall Production
The prestressed slabs are manufactured in 2 indoor production units, each containing 5 beds of up 150m in length. A range of cross sectional profiles can be manufactured, ranging in height from 150mm to 500mm. All slabs are prestressed using a combination of 9.3mm and 12.5mm strands.
The hollowcore is formed using a slip form process. The reinforcing strands are positioned and tensioned, prior to the concrete being cast into position. A dry mix with zero slump is used in this unit. This ensures that the voids do not collapse while the concrete is still fresh. The slabs are allowed cure until cube tests indicate that they have reached their required transfer strength. They are then cut to length, and transferred to the storage facility.
Beams, Columns and Stairs
All frame elements including beams, columns and stair flights are formed in a fully covered 7,500m2 production area. This unit contains approximately 250linear metres of steel moulds. This includes adjustable moulds for standard beams and columns, stair flights and portal frame roof beams. Non-standard shapes can be accommodated by using timber inserts, or in certain instances by using full timber moulds. Project specific custom steel moulds can be manufactured on site in the adjacent steel workshop.
All of the above members are cast using a high strength (typically 50N) self-compacting concrete. This eliminates the need for vibration of the concrete. It also results in a superior finish as it greatly reduces the risk of trapped air pockets, and associated surface blemishes.