A prefabricated concrete component factory uses WOURL 009 release agent to achieve improved component yield and comprehensive cost optimization

A East China component factory specializing in the production of prefabricated concrete (PC) wall panels for residential industrialization has long been plagued by chronic problems in the demolding process: the unstable effect of the original demoulding agent has led to a high rate of demoulding damage, multiple surface defects on the components, and huge rework costs; At the same time, the original mold release agent corrodes the steel mold, and the diluent is prone to deterioration and odor, which continues to drive up operating costs. Fully switching to Shanghai Wenou WOURL 009 Preform demoulding lotionAfter strictly following the standardized application guidance of Wenou, the first pass qualification rate of components in the factory has significantly improved, the maintenance cycle of steel formwork has been extended, the workshop environment has been fundamentally improved, and a comprehensive breakthrough in quality, cost, and efficiency has been achieved.

Challenge

In the large-scale production of this component factory, the demolding process is a key bottleneck that restricts overall efficiency. When using the original release agent, it is difficult to remove the mold, which frequently leads to damage to the edges and corners of the components, and defects such as bubbles and rough surfaces appear on the concrete surface.

On average, 15% of every 100 wall panels require additional surface repairs, which not only consumes a lot of materials and labor, but also seriously affects the delivery cycle and customer satisfaction.

The original mold release agent has insufficient rust prevention performance, resulting in expensive steel templates rapidly rusting in humid environments. On average, a comprehensive rust removal and maintenance must be carried out every six months, which increases maintenance costs and affects production plans.

Solution

Faced with the customer's difficulties, the technical team of Wenou conducted a comprehensive evaluation of the component factory and provided a system solution with "product+method" as the core. Q&A recommends replacing WOURL 009 preform demoulding lotion for the whole line. This product is an emulsified release agent specially designed for concrete preforms, which is suitable for steel molds and plastic films. Its unique film forming technology and formula can ensure smooth demoulding and smooth component surface from the root. The anti rust and antibacterial components in the formula provide a dual guarantee of template and tank stability in a more synchronized manner.

Ask Europe for standardized application guidance, and establish clear and executable operation specifications for customers. First, dilute scientifically, dilute lotion and water in a ratio of 1:3-6, and fully mix evenly. Secondly, paint in a standardized way, and paint the demoulding lotion evenly to ensure that a uniform and complete film is formed on the mold surface. Pour concrete after the white lotion on the mold has completely faded. Finally, manage the template and tank solution. After removing the template, inspect the surface of the template and clean it. Q&A suggested that the demoulding lotion should be prepared immediately after use, and the unused diluted demoulding lotion should be sealed, stored in a cool place, used next time, and stirred again evenly.

achievement

采用问欧方案并稳定运行一个季度后，该构件厂的生产面貌焕然一新，质量指标显著提升，拆模变得轻松顺畅，构件边角完整无损，表面光滑平整，气泡与麻面问题基本消除，需要修补的构件比例从15%下降至3%以下，返工成本和工期延误得到根本性控制。综合成本有效降低，得益于WOURL 009优异的铺展性和高稀释比，单方混凝土的脱模剂成本降低了约20%。钢模板锈蚀现象得到有效抑制，全面除锈保养周期延长，维护费用和停机时间双降。稀释液可短期存放，减少了配料次数，车间异味消失，工作环境得以改善。

Value provided to customers

·提升产品品质与合格率：获得表面光洁、棱角分明的优质构件，减少返工。

·降低综合运营成本：节省脱模剂直接成本，延长高价值模具寿命，降低维护费用。