Concrete production
Concrete moulds
BRIDGE GIRDERS
Lines for the production of structures, for prestressed elements, used as girders in the construction of bridge spans. Examples of bridge beams are: U or W beam, for long-span bridges and major highways, suitable for inclined decks with high torsion. Base width about 1m with variable height up to 1.6m. Spans up to 45mBelow box girders with long lower wings. Base width up to 2.5m, height up to 1.8m,These units are self-supporting. This means that they integrate tension heads into the mold. At one end is a passive head, whose function is only to hold pre-tensioned cables, while at the other end is an active head. The active stressing head contains loosening jacks that allow controlled release of cable tension before it is cut after the concrete has cured.
VERTICAL MOLD
The vertical battery mold is specifically designed to produce full panels at a high capacity factor in a small space. Additional advantages of this production system are that both sides of the precast concrete element are in contact with the casting panel, allowing a high finish on both sides. In addition, the panels are already de-molded in a vertical position, ready for collection, storage and transportation.
ROOF AND PANEL LINES
Long Lines for the production of prestressed elements of a specific shape, which can not be obtained on a "general purpose" prestressed concrete line.These units are self-supporting. This means that they integrate stressing heads into the mold. At one end is a passive head, whose function is only to hold pre-tensioned cables, while at the other end is an active head. The active stressing head contains loosening jacks that allow controlled release of the cables' tension before they are cut after the concrete has cured.
BEDS
The beds are made of a support structure with different positions of drill holes for different widths of elements, on which quick-attachment systems are placed to fix the side forms. A hydraulic version of the bed is also available, where hydraulic cylinders are placed in the inner part of the bed to open and close the side molds against the bottom. A quick-locking system ensures that the side molds are perfectly pressed against the bottom, thus withstanding the force of concrete during casting. Different bottoms are placed on top of this support structure, depending on the size of the piece there will be different sets of bottoms. The bottoms are made of the highest quality casting plate, 6 or 8 mm thick, and can be designed in 2 different ways according to customer requirements. One bottom for each dimension of the beam base, and the side sides closed on the bottom of the bottom. One "universal" bottom with a wider width and the sides sloped over the bottom itself. This solution is more suitable for a wide range of beam base dimensions.
COLUMN MOLDS
Columns are a prefabricated component usually produced in a very wide range of dimensions both in terms of length, width and position of consoles. For this reason, molds for columns can be designed differently depending on the customer's requirements for the components produced.
MONOBLOK MOLD
A mold for the production of complete "rooms" of various sizes for different purposes: for electrical stations, prison cells, bathrooms, cells, etc.The purpose of the system is to produce a "monoblock" of precast concrete, in which the 4 side walls and the floor or ceiling are produced together without having to be joined together on site, thus reducing the assembly time of the structure.The element can be poured in a straight position or upside down, in which case a lifting frame with a hydraulic tilting device is supplied with the mold.
FIXED SIZE STAIR MOLD
If it is necessary to prefabricate a large number of elements with the same dimensions of treads and transitions, it is good to make them in a fixed form.
We suggest cast stairs in a vertical position (in order to get the best possible surface finish for both the top and bottom of the element).
The base plate can be raised with telescopic supports, thus adjusting the width of the stairs.
The number of steps and landings can be adjusted by moving the side separators.
HOUSING UNIT PRODUCTION LINE
A special production system for housing units called 3D-Betoncasco. This method, developed by the Dutch company Casco Totaal, involves building completely prefabricated concrete housing modules under controlled conditions in a prefabricated factory. The modules are then transported to the site and put together in a very short time. Each block is a component of a new construction project.
MOLDS FOR FENCES
The system consists of:
Foundation pillars anchored in the ground
Support pillars: small elements of 20 to 30 cm in cross-section with a "female" profile to connect to the small panels
Panels with a common thickness of 8 to 12 cm, a height of about 1m and variable length (usually from 3 to 6m)
MOLD FOR BOOMERANG ELEMENTS
A mold for producing a "boomerang" beam with a maximum length of 23m and a maximum overall height of 3.7m.
The mold is made by
- A base frame with two metal profiles anchored to the ground, on which parts of the mold slide to change the length of prefabricated products. Side supports slide on the base frame.
- A pair of hinged side walls with a total angle of rotation of 30°, made of cast sheet steel of 1st class, reinforced by brackets in the rear wall.
The sides are modular, making it possible to produce beams of 15, 19 and 23 meters in length. The base plate has a fixed height.
BATTERY MOLDS
The vertical battery mold is specifically designed to produce full panels at a high capacity factor in a small space. Additional advantages of this production system are that both sides of the precast concrete element are in contact with the casting panel, allowing a high finish on both sides. In addition, the panels are already molded in a vertical position, ready to be picked up, stored and transported.
One side wall is stationary, while the others can be moved using hydraulic cylinders or electric motors, according to the height of the side walls and customer requirements.
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