Elematic battery mold processes EN.pptx [Read-Only]elematic.studio.crasman.fi/pub/Marketing/... ·...

ELEMATIC BATTERY MOLDPROCESSESFOR WALL PRODUCTION

Battery molds vs. circulation line

BATTERY MOLD CIRCULATION LINE

Both sides are made against steel mold

� Smooth paint-ready surface

Top side has to be trowelled

� Quality variations may occur

Both surfaces get cured in similar

circumstances

� No bowing because of different

shrinkage

Bottom surface is denser than top

� Possible bowing because of different

shrinkage

Concrete is enveloped in the mold while

curing

� No moisture loss or condensation of

extra water

Top surface is open

� Possible moisture loss or condensation

of extra water

Panels are produced and handled vertical

� No need for tilting

� Saving of building space

Panels are horizontal during production

� Need for tilting before achieving the

design strength

� More factory building is needed

Applying retarder agent to the mold is

difficult

� Exposed aggregate finish is not possible

Retarder and cladding materials can be

used

�Various finishes can be used

Elematic battery molds

Elematic has two different battery mold systems available:

- Traditional battery mold system

- Cold shutter plate system

April 3, 2012 Elematic battery mold processes3

TRADITIONAL BATTERY MOLDPROCESS


Battery mold production process

Starting from completion of curing

1. Hydraulic clamping rams are released

2. End wall is moved enough to allow the cured panel(s) in the first cell to

be released and removed by an OH crane from the side of the mold.

3. Intermediate mold plates are moved one by one and cured elements

removed by an OH crane from the side of the mold.

4. Cleaning, oiling, reassembly of side forms etc. and placing of inserts and

reinforcement can start immediately after removal of elements from the

cells.

5. The battery is reassembled and tightened after preparation work in all

cells has been completed and inspected.


Battery mold production process

6. Concrete is cast by a casting machine or casting skip, top surface is

smoothened and preferably covered to prevent dehydration.

7. Concrete temperature is increased and controlled during curing in

relation to speed of production, final strength and required stripping

strength.


General concerns

• Surface quality

• Compaction

• Curing

• Labor

- Number

- Skill requirements

• Working environment

• Changeability, flexibility


Surface quality

• Manufacturing in a battery mold gives plain and smooth surfaces on both

sides of the panel

• Concrete mix design affects the surface quality and Elematic has the know-

how and resources for finding the optimum recipe

• Magnetic fastening system for openings saves the mold surfaces from

damages

• Magnetic fastening system also makes furnishing work fast and efficient


Compaction

• Wall panels with openings have been manufactured successfully in battery

molds for decades.

• Battery molds included in Elematic’s quotation have built-in vibrators to

ensure proper compaction even with ordinary concrete mixes.

• Introduction of SCC has made it easier, faster and even more economical.

• Sufficient tightness of the casting cells is achieved by seals on the edges of

the side forms.


Enclosed curing

• Battery mold provides the most efficient and uniform accelerated curing

environment.

• As all the surfaces of the panel – with the exception of the top – are

surrounded with steel, no moisture is lost during the curing.

- no moisture loss = no loss of strength

- no humidity control system is needed


Labor

• Skills requirements

- Unskilled worker can be easily trained to work on a battery mold

- No special hand-skills are needed

• Number of workers per shift (in battery mold lines)

- 11 workers per each 3-battery line

- In addition:

• one crane operator for each battery mold line

• 3 men for B&M plant

• 3 men for stock yard


Working environment

• SAFETY

- Elematic battery molds are equipped with stairs, catwalks and railings for safe working on

the top of the mold.

- The top surface is flat with minimal obstructions.

- Movements of the leaves of the mold are slow and made manually No danger of men

getting squeezed.

• COMFORT

- Elematic battery mold is a compact package and emits very little heat

- Vibrators are enclosed inside the battery and the vibration energy goes into the concrete

- Floors are flat and free from pits, which helps cleaning (also and important safety issue!)


Typical casting cell layout

Opening / First cell

Opening / Second cell

Cleaning and fitting

Cleaning and fitting (upper section)

Casting

Working on top of a battery mold


Working on top of a battery mold


End product

COLD SHUTTER PROCESS


Cold shutter plate

22

Furnishing

• The cold shutter plates are

furnished outside the battery

mold.


Furnishing

• Furnishing racks are situated in a

separate area close to the battery

molds


Furnishing


Furnishing


Side forms are and opening molds are fastened by Elematic

magnets

Furnishing

• The furnished cold shutter plates

are then transferred into the

battery mold.


Closing the furnished mold


Cold shutter plates in a battery mold


Battery mold ready for casting


Casting


Casting

• Battery molds are always cast up to

the surface.

• The bottom of the mold is

adjustable.


Vibrating

• The vibrators are usually included

in the Elematic delivery.

• In case the vibrators aren’t

included, poker vibrators can be

used for vibrating (see picture).


After casting

• The cast and pre-cured concrete

element is moved from the mold

for the rest of the curing.

• This accelerates the casting cycle


After casting


END PRODUCT


Close-up of a battery-mold-made panelsurface


Ornament on a battery-mold-made panel


Close-up of a battery-mold-made panelsurface with ornament


Close-up of a battery-mold-made panelsurface and edge


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