Vertical Battery Mould

 

Vertical Battery mould is designed especially to produce solid panels at a high productivity ratio in a small space. Additional benefits of this production system is that both sides of the prefabricated concrete element are in contact with the casting plate, thus allowing high finishing on both sides. In addition, panels are demoulded already in vertical position, ready for collection, storage and transportation.

 

The structure is made of a base frame with rails where several sets of vertical elements, called side walls, are placed. Each side wall is made of 10mm high quality plates opposite to the casting, reinforced by steel sections that allows to achieve a robust structure able to opposite to concrete pressure during casting.

 

One side wall is fixed, all the other are movable by means of hydraulic cylinders or electric gearmotors, according to side walls heights and customer requirements.

 

The movement of the side walls can be on one or two sides of the fixed wall, thus creating a single or double opening battery mould, with 2 structures working independently one from the other. Side walls are moved both for assuring the working space for mould preparation before casting and for allowing the possibility to change the thickness of the elements to be produced. Manual deplacement of side walls is possible.

 

In the internal part of the side walls there are the horizontal bottoms at variable height, these elements are the lower limit to the casting and act like a support for the concrete element. In the same position there are also the vertical separators, that can be placed in different position in order to produce several panel lengths.

 

On the side walls it’s possible also to fix other accessories like windows and doors inserts (fixed by Bianchi magnets mod. BI-BLOCK , rebar spacers, etc.

 

Any coupling between movable parts of the mould in contact with concrete 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.

 

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.

 

Effective lock of the battery while casting (in order to opposite to pressure of the concrete) is granted by 2 hydraulical ties placed on each one of the 2 lateral faces of the battery, and by several manually operated ties placed in the upper and lower part of the mould.

 

Battery mould is complete with walkways with parapets and access stairs to the high part of side walls during preparation, casting and de-moulding phase.

 

Battery 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 battery 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 can be insulated by plastic canvas or plastic panels.

 

Technical figures:

  • Number of pockets: up to 20 and more
  • Height of the panels: up to 4m. higher dimensions available upon study
  • Infinite possibilities of panel thickness and length
  • Filling of single mould compartments is possible