Precast
concrete moulding have revolutionized the construction industry, offering an
efficient and cost-effective way to produce a variety of concrete elements.
Today these moulds are essential tools in the manufacturing of standardized and
finished precast concrete elements. They enable the mass production of concrete
elements and components with consistent quality and design at off-site
production facility, which are then transported and assembled at the
construction site. This method not only saves time and reduces labour costs but
also minimizes on-site environmental impact.
Among
the various precast concrete moulding methods, the battery moulds are very
popular due to their significant advantages and applications especially in
producing precast building elements.
What
is Battery Mould
A
battery mould is a large piece of industrial equipment consisting of a series
of vertical casting chambers, also known as cells or pockets, to vertically
cast multiple large concrete panels or wall elements simultaneously. The casting
chambers can be adjusted in size using shutters to create elements with
specific dimensions. Also the concrete strength is gained in the same moulds by
integrating the heating and vibration system.
The
production of precast concrete elements in a battery mould is a space-saving
alternative to production on tilting tables or at circulation plants (carousel
plants). Vertical production ensures very good utilisation of the production
area and reduces the transport effort.
The
battery moulds are suitable for making panels as walls, floors and other flat
pieces of solid concrete with non-prestressed reinforcement, requiring
smoothness on both side surfaces.
Key
Components of Battery Mould
Bulkheads
(or Partition Walls): These are parallel steel
walls that divide the battery mould into multiple individual casting chambers.
They create the "cells" of the battery mold.
Formwork
Shutters (or Side Walls): These define the perimeter
and edges of the precast concrete panel. They can be adjusted in height and
width, and fitted with elements for doors, windows, or other apertures in the
panels.
Bottom
Mould (or Base Plate): This forms the underside
of the precast concrete element. In some systems, the bottom formwork can also
be adjustable in height to create panels of different thicknesses.
Movement
System: This is a crucial part of the battery mould
and is typically a hydraulic or electric-mechanical system used to move the
bulkheads and shutters for opening, closing, and extracting the concrete
panels.
Heating
Systems: These are often integrated to accelerate the
concrete curing process, increasing productivity.
Sealing
Gaskets: Placed between the formworks, these gaskets
ensure a tight seal and prevent concrete leakage from the chambers.
Vibration
System: Integrated vibrators are used to compact the
freshly poured concrete, ensuring a high-quality product with smooth surfaces.
Locking
Mechanisms: These ensure that the mold is securely
closed before and during the concrete casting process
Advantages
of Battery Mould
This
manufacturing method provides significant advantages in productivity, quality,
space efficiency, flexibility and versatility compared to traditional
horizontal casting methods.
High
Productivity and Space Efficiency
Maximum
use of factory floor space: A battery mould casts
panels vertically in compact, parallel chambers, occupying a minimal footprint
while producing a large volume of panels simultaneously.
High-volume
output: The system can produce multiple panels at
the same time in one operating cycle. More advanced "cold shuttering"
versions can significantly accelerate the process, enabling two casting rounds
per day and doubling capacity.
Accelerated
curing: Integrated heating systems that use hot
water, thermal oil, or steam can be incorporated to speed up the concrete
curing process. Some systems allow panels to be demoulded and removed for final
curing within a few hours, freeing the mould for the next batch.
Centralized
operation: The entire process, from vibration and
heating to locking, is controlled from a central panel. This streamlined
approach increases overall production efficiency and reduces labour
requirements.
Superior
Product Quality
Smooth
finishes on both sides: Unlike horizontal casting,
which requires separate finishing for the top surface, a battery mould uses
high-quality steel plates on both sides. This results in straight, smooth, and
consistent finishes that are often ready-to-paint.
High-quality
compaction: Integrated high-frequency vibrators
effectively compact the freshly poured concrete, eliminating air bubbles and
ensuring a high-quality surface finish.
Dimensional
precision: The rigid steel structure and powerful
hydraulic clamping system ensure that the panels are cast with high precision
and tight dimensional tolerances.
Flexibility
and Customization
Flexible
product sizing: Adjustable bulkheads and side shutters allow
for the production of panels with various sizes, thicknesses, and features,
including openings for windows and doors.
Customizable
capacity: The number of casting chambers can be adjusted
based on production needs. Manufacturers can also add extra cells to increase
production capacity.
Versatile
construction: Battery moulds are available in
"mono" or "duplex" configurations, where the latter
features a central fixed panel that allows for independent filling of separate
chamber sections.
Portability
and Reusability
Mobile
production options: Some battery mould systems
are modular and semi-mobile, making them easy to dismantle, transport, and
reassemble at different construction sites. This reduces transportation costs
and time for precast panels.
Long-term
investment: Since the durable steel forms can be reused
thousands of times, the investment cost per unit of production is lower
compared to one-time formwork used for site-cast concrete.
Applications
of Battery Mould
Battery
moulds are used in the precast concrete industry for the vertical, simultaneous
production of solid concrete elements like:
Walls:
Battery moulds are primarily used to manufacture precast concrete wall panels,
including solid walls, partition walls, and facade elements. They are
especially useful for creating complex or architectural wall elements with a
high-quality finish on both sides.
Slabs:
The moulds can also be used to produce solid floor and ceiling slabs in various
sizes and thicknesses.
Other
structural elements: These moulds are also used
to produce other precast components, such as balconies and stairs.
Elements
with special requirements: The mould's vertical
orientation and the ability to integrate specialized equipment allow for the
creation of unique products such as elements with doors, windows, and other
built-in parts, components with specific surface textures, which can be
achieved by adding form liners to the mould, and elements with all-around tongue-and-groove
profiling for better structural connections.
Battery
moulds play a crucial role in the modern construction industry. Their ability
to produce consistent, high-quality products simultaneously in an efficient and
cost-effective manner makes them an indispensable tool. As the demand for
sustainable and innovative construction solutions grows, the use of these
moulds is expected to expand, further enhancing the capabilities of the
construction industry.
