DUPLEX FORMWORK - for high output when concreting with a casting process

With conventional immediate formwork removal, the formwork is removed from the finished part shortly after moulding and compacting. The mould is immediately available for the next cycle. A prerequisite for high production quantities is the use of very stiff or earth-moist concrete mixes. However, as the stiffness increases, the resistance to compacting increases dramatically and this can lead to cavities and rough surfaces. The early removal from the mould also impairs the dimensional stability goals for the end product. With the casting process, the fluid to plastic concrete, which is significantly easier to compact, hardens in the mould. The finished parts therefore have a very high level of dimensional stability and excellent surface characteristics. Complex concrete parts with very high functional and visual requirements can be manufactured. However, the disadvantage is the long hardening times required and the lower production rates associated with this for each moulding device. The precast parts plant must stock significantly more moulds for the same production volume and this would ultimately increase the unit prices for the concrete parts. So, this presents a problem for the precast plants: High quality products are very time-consuming to make and enormously cost-intensive. In cooperation with IAB Weimar gGmbH, BETA have therefore developed a moulding device for pipes, shafts, frames or containers that will effectively solve this problem. For 65 years, BETA has been involved in finding an appropriate solution with innovative machines and systems for the complete process in precast concrete plants. Alongside the 3D design, our strengths are the manufacturing of complex steel formwork and moulds. In this context, the basic concept of the "dual effect mould" arose - a formwork with multi-dimensional structure with regard to function and time. The advantages of the casting process are used without the whole moulding device being out of use for the duration of the concrete hardening. The system comprises primarily a "Main mould" with concreting device, compacting system, handling systems for building and removing the formwork as well as several so-called "Support formwork" units. After the core, jacket and profile rings are shuttered in and the concrete is filled in and compacted, the "main mould" is immediately removed. The complex system components are immediately available for the next cycle and are therefore optimally utilised. The freshly moulded concrete element is stabilised only by a cost-effective "support formwork" until hardening has finished. After the hardening, the formwork is removed and the finished part is further processed.