The Process Manufacturing Process
Components



Manufacturing Process

Each Smartboard panel is individually manufactured utilizing a unique system which gives Smartboard its exceptional quality and performance. Smartboard's manufacturing process consists of six modules, with a choice between a manual operation and a fully automated operation.

Each module has a number of different procedures that link together forming the complete process. Specially engineered forms are mechanically conveyed along the system where they are prepared, filled with material, and finished employing state-of-the-art pneumatic and electronic controls together with precise timing and intricate movements that result in our advanced technology. Continuous quality control, meeting ASTM requirements, results in consistent quality cement board.

Components
(Click on a module for more info)

Manufacturing Process



Curing Oven



Module 1 - Raw material storage and mixing

The Smartmix operation prevents contamination and accurately blends raw materials to specified mix proportions. This system provides continuous quality control resulting in consistently high quality cement board. The equipment is designed to operate in any climate and to conform to plant areas with space limitations.

Module 2 - Rack unloading station

When the curing process is complete, the filled forms are removed from the curing chamber by forklift and brought to the unloading station where the boards are removed from the forms, placed on skids and processed for shipping. The forms continue along the conveyor and the process repeats.


Module 3 - Form preparation

The form preparation for production consists of three operations.

  1. Cleaning - The form is cleaned by rotating brushes which remove any debris.
  2. Form release - Release agent is applied to facilitate stripping of the board after curing.
  3. Bottom scrim placement - A fibreglass reinforcing mesh is sheared to length and placed into the form.


Module 4 - Form pouring

The pouring process involves five operations.

  1. Mix conveying - Wet mix is transferred from the mixer into a holding hopper suspended above the conveyor.
  2. Fill head - The mix is dispensed through the fill head as a prepared form passes below.
  3. Levelling roller - Dispenses the mix evenly throughout the form.
  4. Vibrating table - Precisely embeds bottom scrim into the mix.
  5. Top scrim placement - A second fiberglass mesh is sheared to length and applied to the mix.
  6. Finish screed - The board is then finished with a combination roller and screed operation.


Module 5 - Rack loading station

Filled forms are transferred from the conveyor onto a loading skid to await removal to the curing operation.


Module 6 - Curing chamber

The filled forms are removed from the unload station by forklift and placed on specialized racking in the curing chamber. Optimal heat and humidity are maintained throughout each panel during the curing process.

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