Brand new fully equipped precast concrete factory in Hungary

One of the major Hungarian construction companies, based in Budapest and specialised in the design and construction of industrial, public, commercial and logistic buildings, recently opened a new precast production facility. The new plant, which has just been inaugurated, is engaged in the production of precast reinforced and prestressed concrete structures. Its services include design, manufacture, delivery and assembly; enabling it to provide quality construction in a full range of structural projects. To develop their precast production, they requested Construx Weckenmann to design a complete package of molds, machines and accessories to produce precast walls, columns, stairs and reinforced and prestressed beams.

Construx Weckenmann supplied a whole range of molds:

Hydraulically operated adjustable mold for prestressed I and T beams;

Casting bed with modular side-shutter system for prestressed rectangular beams;

Hydraulic battery molds for columns with integrated foundation feet;

Hydraulic battery mold for columns;

Fully electrically adjustable double side-pour stair mold;

Hydraulically operated tilting tables.

Hydraulically operated adjustable mold for prestressed I and T beams

The customer insisted on getting a flexible solution for the manufacturing of their different types of prestressed I and T beams. In between 2 abutments, Construx Weckenmann installed a 100m long single binder mold to produce these concrete beams. The mold is divided into 4 sections of 25m each. Each of these sections can be moved individually as well as combined with one or more of the other sections. The complete mold sits on rails and has a fixed side and a movable side. Opening and closing the side panels is done hydraulically. Operating the hydraulic rams that move the panels can be done in 2 ways: with the fixed control panel or with the remote control. A clamping system underneath the panels fixes the panels onto the rails. The side-forms are divided into different segments of 1,5m, 2m, 3m and 6m. The 100m long mold is designed to cast several prestressed beams in a row. The mold allows to cast a great variety of girders.

The typical I and T beams with lengths between 13m and 31m have a very wide range:

Overall girder height: from 1,050mm to 2,000mm;

Web thickness: from 120mm to 320mm;

Top flange width: from 400mm to 800mm;

Top flange thickness: 100mm to 300mm;

Bottom flange width: from 400mm to 600mm;

Bottom flange thickness: 300mm to 400mm

Adjusting the geometry of the mold, in order to make the required girders, is done with cut to measure 21mm plywood which is fixed between the steel mold parts. The soffits need to be made out of plywood and placed on the rails. To create a safe working environment, the fixed side of the mold is equipped with a working platform.

Casting bed with modular side-shutter system for prestressed rectangular beams

Construx Weckenmann also installed a formwork system to manufacture prestressed rectangular beams. It consists of a casting bed with modular side-shutters. These side-forms can easily be fitted onto the 100m long and 2m wide casting bed. The alternating 25mm increment pattern of the bed corresponds with the holes in the bottom of the panels. Construx Weckenmann also included an extra fixing system which consists of extension plates with the same 25mm increment pattern and a horizontal connection to the side-forms. This system can be used when both sides of the mold are too close together and out of reach from the 25mm hole pattern of the bed. In length, the mold is conceived as a modular system, it has 13m, 6m and 3m long parts. This avoids mold parts sticking out too far beyond the prestressed concrete elements, which would cause a large gap in between 2 elements what would result in a waste of strand and a pour bed efficiency. The panels can be used for all sorts of prestressed elements with a height of up to 600mm and a width between 300mm and 1,000mm, with 25mm increments.

The mold is conceived as a rigid flat panel system and consists of panels which are all 273mm high. These panels can be used separate or on top of each other, thus avoiding finishing the concrete surface too deep down. Both sides of the mold are interconnected at the top of the panels with tie-rods and fixed onto the bed with bolts through the holes in the base or by means of the extra foot plate fixing system. The distance in between both sides of the mold can be adjusted in accordance with the 25mm increment pattern of the bed. The flexibility and modularity of this system, in height and in length, allows for future extensions by purchasing more and different sizes of panels.

Hydraulic battery molds for columns with integrated foundation foot

For producing columns with a foundation foot and multiple corbels, Construx Weckenmann equipped 2 of their standard Bibat molds with an adjustable foot mold at one end of each pocket. A standard Bibat configuration consists of 4 full steel panels: 2 fixed panels in the centre and 2 movable panels on the outside, thus creating 2 pockets per mold. The panels are opened, closed and secured by means of hydraulic cylinders, hence without any manual intervention. Both fully hydraulically operated double battery molds are 16m long and have 4 integrated box-outs for corbels per pocket, 2 on each side of each pocket. All 16m long pockets are divided in 2 sections of 8m length. These can be moved individually as well as together.

Each Bibat has 2 integrated independently operating molds for the foundation feet. The opening and closing of the foot molds is also done hydraulically. In between the 2 fixed panels and on top of the foundation foot molds are working platforms to create a safe working environment. The full steel side panels of the molds are divided into different segments and mounted on rollers to move sideways. This allows to integrate the corbel pockets onto the columns. The corbels are formed by fixing plywood into the rectangular frame of the pockets. These box-outs as well as the timber soffits, which sit on a height adjustment system, must be made to measure by the customer. The height adjusters consist of 100mm x 100mm square tubes of different lengths with 50mm increments. Depending on the width of the columns, the soffit support system can be set in a single or a double configuration. Operating the hydraulic rams that move the panels can be done in 2 ways: with the fixed control panel or with the remote control.

A wide range of columns can be made in these Bibat molds:

Overall column length: 16m or 2 x 8m;

Column width: from 300mm to 900mm;

Column thickness: from 300mm to 900mm;

Maximum foot dimensions: 3000mm x 3,000mm;

Maximum foot thickness: 600mm;

Possibility to make multiple corbels on all sides of the columns.

Hydraulic battery mold for columns

The third Bibat hydraulically operated battery mold supplied by Construx Weckenmann didn’t have adjustable foot molds at the end of each pocket. Except from the feet, its configuration and other features is similar to the 2 other Bibat molds:

Overall column length: 16m or 2 x 8m;

Column width: from 300mm to 900mm;

Column thickness: from 300mm to 900mm;

Possibility to make multiple corbels on all sides of the columns.

Fully electrically adjustable double side-pour stair mold

This double mold consists of 2 identical Sidecaster stair molds with 18 fully electrically adjustable risers and goings.These Sidecaster molds are suitable for producing stairs vertically (steps facing sideways). This manufacturing method ensures a perfect smooth finish on 3 sides of the stairs. Each mold consists of a fully adjustable panel at a fixed position and a flat panel that can be moved sideways and back and forth. Both panels sit on a frame on which a height adjustment system supports the timber soffit. The side movement allows to put the panel at its right position in order to connect with the opposite panel. The transverse movement allows to adjust the throat of the stairs and to demold and open the mold in order to take out the stairs, clean and oil the mold and put in the reinforcement. Both movements are carried out by means of rollers, a mechanic chain drive and a drive wheel. The mold has a synchronized electric adjustment of risers and goings. All steps can be electrically adjusted at the same time.

The adjustment mechanism for risers and goings, consists of 2 sets of synchronized actuators: 2 electric actuators adjust the distance in between the individual steps and 2 electric actuators adjust the angle between the steps. Consequently, goings and risers are electrically controlled. The fronts of the risers lie back 21mm in order to screw 21mm thick plywood strips, cut out to measure, onto incorporated timber blocks. As mentioned above, adjusting the width of the stairs (height of the pour) is done by a series of height adjusters which fit on the base frame of the mold, and which serve as supports for the timber and plywood soffit. This plywood soffit needs to be cut to measure by the customer. After the mold is adjusted, the panels need to be secured by means of ties: underneath and over the top. Both sides of the mold have full steel working platforms with access stairs on both ends. The molds have an extended last step at each end, to allow for landings of up to 400mm. The angles of the landing panels can be controlled manually by means of very precise spindles.

Both Sidecaster molds have the same configuration:

Number of steps: from 4 up to 18;

Width of the stairs: from 800mm up to 1,600mm;

All steps with straight fronts;

Goings adjustable from 220mm to 320mm;

Risers adjustable from 150mm to 200mm;

Top and bottom landings up to 400mm;

Throat: from 120mm to 250mm.

Hydraulic tilting tables

The 3 tilting tables Construx supplied have a length of 12m and a width of 4,5m. One of the tables is equipped with 1 single 10mm thick steel sheet, without any welds or joints. The steel plate is stripped, sandblasted and polished with Scotch-Brite and has a tolerance of +/-1,5mm on 3m length. That table also has extensions on the 12m tilting side to allow to put side-forms, hence using the full 4,5m width of the table. The 2 other tables are provided with a timber sheeting. The top structure of all 3 tables is subdivided into a top pallet and a tilting frame, with vibration absorbers fitted in between both. This gives the tables a very smooth and equal vibration pattern with no loss of energy in the frame or in the ground. The tilting frame is tilted by means of 3 telescopic cylinders; these rams are driven by means of an hydraulic aggregate with 3 pumps in order to synchronize the stroke of the 3 cylinders.

The pallet and the frame are not structurally connected. The frame is connected with hinges onto 2 stable and fixed ground beams. These ground beams accommodate the cylinders and are equipped with floor supports. The tables have a tilting angle of 80° and can carry a load of 1,000kg/m². The maximum overall tilting capacity is 39T. Each table has one 12m long and 400mm high plywood sheeted side-form, divided in 2 fixed sections of 6m length. These forms are bolted against the underside of the table. The tilting tables are all equipped with vibrator connection plates.

Shaping the future of concrete

Construx Weckenmann complied with the short lead time and with the customers requirement to obtain a multifunctional, flexible and versatile solution to manufacture their concrete elements. The outcome of achieving these objectives was a very satisfied customer. Construx Weckenmann is an engineering-driven manufacturing company relying on the commitment, creativity and experience of its employees. Their aim is to establish a partnership, rather than to be a supplier, in providing turnkey solutions for precast and on-site formwork issues.