Mould for the production of complete “rooms”, of different dimensions for different purposes: electrical substations, prison cells, bathrooms, pods, etc.
The goal of the system is to produce a “monoblock” in prefabricated concrete, where the 4 lateral walls and the floor or the ceiling are produced together without the need to be coupled together onsite, reducing in this way the time for assembling the structures.
The element can be poured in straight or upside down position. In the second situation, a lifting frame with hydraulical tilting device is supplied with the mould.
The mould generally consists of a base frame, where the base plate is staying.
Lateral sides can be opened and closed hydraulically or manually with fast-locking devices.
In the internal part of the mould there is an hydraulically shrinkable “core” mould that can retract before demoulding the complete module. Alternatively the core can be made into some separated parts that can be combined and decomposed manually according to a precise sequence during the assembling.
Generally, the floor or the ceiling are manufactured apart, on a separate table, and coupled with the monoblock in a second stage.
The equipment is complete with walkways, parapets and access stairs to the high part of the mould during preparation, pouring and de-moulding phase.
Any coupling between moulds moving parts is equipped with rubber gasket in order to avoid concrete leakages. The gasket that can be conceived either underneath the casting surfaces, with metal chamfer bolted on the casting plates, or welded on the shuttering, with special shape (GF type) that guarantees the presence of the chamfer in the rubber itself.
Mould Sides and/or the internal core can include a vibration systemconsisting of a series of vibrators that can be electric or pneumatic. The vibration compacts the concrete by removing air and increases its mechanical strength after curing. Furthermore, vibration allows using concrete with less moisture and accelerates the curing process, in order to increase productivity. Click on this link in order to examine all the range of Bianchi product in vibration for prefabrication.
The heating system of the prestressed lines also increases productivity by accelerating the curing process. This system consists of a series of finned pipes positioned along the lateral sides or even underneath the bottom base, where hot water or industrial steam flows at the pressure of 4-5 bar. The external part of the lateral sides is covered by isolation canvas or plastic panels.