Civil Prefabrication


 

Bridge Beams

 

Structural production lines, for Prestressed elements, used as girders in bridge span construction.

Examples of bridge beams are:
 

  • U or W beam, for long span bridges and major motorway schemes, suitable for skew decks with high torsion. Base width about 1m with variable height up to 1,6m. Span up to 45m
  • Box beams with long lower wings. Base width up to 2,5m, height up to 1,8m,

These equipments are self-supporting. It means that they integrate the stressing heads into the mould. At one end will be the passive head, whose function is only to retain the pre-stressed cables, while in the other end is the active head. The active stressing head incorporates slackening jacks which allow a controlled release of tension of the cables before these are cut after the curing of the concrete.

The mould is dedicated to the element to be produced, generally conceived with a lower baseframe where the self-reacting structure is inserted and where the bottom base is placed.

The lateral sides are opened and closed with hydraulic devices, and tightened with special fast-locking devices.

An upper formwork, retractile if required by the element shape, is dropped from above, and his movement is controlled by hydraulic devices.

In all the bridge beams mould types, Any coupling between tables 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 can include a vibration system consisting 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 bridge beams moulds 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.

Essential equipments in a prestressing lines are the hydraulical units and jacks that allows the tensioning of each single strand, and the detensioning of all the line in a single stroke. All Bianchi range of these machines is available at this link

 

Mould for New Jersey barriers

 

Moulds for manufacturing all kinds of New Jersey barriers, manufactured as per client´s designs and specifications, complying with local homologation standards, for example CE marking.

Moulds with one or more pockets (up to 4) with the required measures for manufacturing the desired amount of barriers.

The New Jersey barriers can be manufactured with the element in straight or upside down position, according to customer requirements. In the second case a lifting beam with turning device is needed.

 

Mould for Retaining Walls

 

Soil reinforcement is a key element for road, rail, hydraulic or civil engineering structures. The system is composed by

  • Geosynthetic reinforcement: tendons of plastic material of different strength
  • Steel reinforcement
  • Concrete facing. Application of precast concrete panels coupled together by very accurate connection system. Panels have a standard dimension of 1,5×1,5m, with different finish types (standard, natural stone or with matrix), a very special shape of the male/female connections, and are connected one to the other by architectural elements called “columns” or “corner”. The mold set is made by 5 different equipments, each of them needing a very accurate assembling and a very advanced sheet cutting and bending skill.