Manufacturing Process


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Manufacturing Process

  1. 1. Manufacturing Process <ul><li>Using the floor mold provided by Living Modular workers complete the task of securing the plumbing, rebar rod and 6x6 rebar mesh. A special mold release agent is applied to release the mold from the concrete once is has cured. No concrete will be poured until all items have been checked and inspected. </li></ul>
  2. 2. Manufacturing Process <ul><li>Hydraulic concrete is poured into the floor mold . Hydraulic concrete is used for the floor due to its high strength and wear resistance against foot traffic. The concrete is constantly vibrated during pouring to prevent any air bubbles from being trapped in the slab. </li></ul>
  3. 3. Manufacturing Process <ul><li>The floor slab is leveled; however, there is no need for a smooth float finish as the slab will be inverted and the part which is now visible will be the bottom of the slab. </li></ul>
  4. 4. Manufacturing Process <ul><li>After the floor slab has cured the mold and slab are flipped upside. </li></ul>
  5. 5. Manufacturing Process <ul><li>The concrete floor is removed from the form and placed on a skid where it will remain throughout the rest of the production process. The top surface of the slab is very smooth having been formed by the mold and requires no hand finishing. </li></ul>
  6. 6. Manufacturing Process <ul><li>The inner mold forms are placed over the floor slab. The production work of the inner molds was done concurrently with the pouring of the floor slab. </li></ul>
  7. 7. Manufacturing Process <ul><li>This is a inner mold placed on a floor slab. Note the rectangle to the left of the mold. This is a vacuum breaker which retracts to aid the removal of the inner mold from the module after pouring. </li></ul>
  8. 8. Manufacturing Process <ul><li>Prior to pouring the inner mold has had all of the pluming, electrical, 6x6 rebar mesh and 3/8” rebar rods installed. The quality control supervisor will inspect all work before permitting the pouring of concrete. </li></ul>
  9. 9. Manufacturing Process <ul><li>The walls of the outer mold are sprayed with a water based release agent just prior to the insertion of the inner mold. </li></ul>
  10. 10. Manufacturing Process <ul><li>The inner mold is inserted into the outer mold. Once both molds are tightly sealed together and a final inspection is performed the cellular concrete can be poured. </li></ul>
  11. 11. Manufacturing Process <ul><li>The walls of the outer mold fold away from the inner mold to allow for the removal and insertion of the inner mold. </li></ul>
  12. 12. Manufacturing Process description <ul><li>The cavity seen here between the 2 molds is then filled with cellular concrete (top view). This is what forms the walls of the modules. </li></ul>
  13. 13. Manufacturing Process <ul><li>The cellular concrete completely fills the wall cavities and flows across the top of the inner mold. This forms the roof of the module. </li></ul>
  14. 14. Manufacturing Process <ul><li>Once the roof section is full steel angles are lowered on each side. These angles are both used to form the slope in the roof for water drainage and the parapets. The parapets extend above the roof on all sides and act as gutters channeling water toward the down spouts. Once the concrete begins to harden the parapets are poured and the roof is floated as smooth as possible. </li></ul>
  15. 15. Manufacturing Process <ul><li>After allowing the concrete to cure the module and inner molds are removed from the outer mold. Note that polystyrene has been used as a block out material for custom door sizes. </li></ul>
  16. 16. Manufacturing Process <ul><li>Once free of the outer mold, the inner mold is lowered and one wall is retracted . The vacuum breaker at the rear of the module is retracted and the inner mold is removed from the module </li></ul>
  17. 17. Manufacturing Process <ul><li>Now that the module is free standing, rebar rods are put in place to support the inner walls. A layer of 6x6 rebar mesh is attached to the rebar in preparation for the inner wall molds. </li></ul>
  18. 18. Manufacturing Process <ul><li>The inner wall forms are placed inside the module and the concrete is poured through the fill-holes in the roof. </li></ul>
  19. 19. Manufacturing Process <ul><li>Concrete being poured through the fill-holes in the roof to create the inner walls. The cellular concrete expands due to the air entrainment which causes it to fill every void in the mold. </li></ul>
  20. 20. Manufacturing Process <ul><li>The end cap panels are constructed and poured in a way that is very similar to the floor slabs. However, the end cap panels are poured with cellular concrete instead of hydraulic concrete </li></ul>
  21. 21. Manufacturing Process <ul><li>This photo is of an end cap panel just after pouring. Once the concrete begins to harden it will be floated as smooth as possible. </li></ul>
  22. 22. Manufacturing Process <ul><li>After the end caps have cured they are placed on the modules with a small crane. Once properly aligned they are welded in place. </li></ul>
  23. 23. Manufacturing Process <ul><li>After the end caps are welded in place the seams are filled with backer rod, a special concrete sealant caulk and grout. </li></ul>
  24. 24. Manufacturing Process <ul><li>The modules are now skim coated to remove any imperfections on all surfaces both inside and out. </li></ul>
  25. 25. Manufacturing Process <ul><li>Modules are now textured, painted and finish. All electrical and pluming work is completed and tested for proper operation. The quality control supervisor does a final inspection on the units prior to shipping. </li></ul>
  26. 26. Transporting Modules <ul><li>Modules are moved wihtin the factory on high-pressure inflatable mats similar to a hovercraft bag. </li></ul>
  27. 27. Transporting Modules <ul><li>Modules being transported by rail from the factory in Mexico to the development site. </li></ul>
  28. 28. Transporting Modules <ul><li>Module arriving on site for installation. The installation process of the 36 square meter homes takes less than 2 hours. </li></ul>
  29. 29. Installation Process <ul><li>Using a 70,000lb crane the modules are positioned on the foundation or pre-prepared form. </li></ul>
  30. 30. Installation Process <ul><li>Modules are aligned and leveled. </li></ul>
  31. 31. Installation Process <ul><li>Modules are welded together and all joints are sealed and coated. </li></ul>
  32. 32. Standard Home <ul><li>Completed Living Modular home (36 square meters) </li></ul>
  33. 33. Development <ul><li>Large low cost housing development in Mexico. </li></ul>