Construx - Shaping the Future of Concrete - en

Shaping the Future of oncreteYour Partner in Precast & On-Site Formwork

EN

Shaping the Future of oncreteYour Partner in Precast & On-Site Formwork

EN

CONSTRUX, YOUR PARTNER IN PRECAST AND ON-SITE FORMWORK

The Construx team

Ward Demyttenaere and Anthony Jannes Managing Directors

10 years

Dear customers,

We are proud to present our new catalogue: “Shaping the Future of Concrete”.This brochure gives a global overview of our achievements in the past 10 years.You should use the catalogue as a guideline to convince yourself that Construx is the ideal partner to realise all your precast and on-site formwork projects.It can be a basic column box or a fully integrated carrousel system or anything in between or far beyond.The brochure is only a synopsis and you should not hesitate to consult us for projects you did not find in this overview.We are not a company with high-brow declarations but we are truly convinced of the importance of defining our mission statement, our vision and our strategy in order to give our customers and other partners a clear view of what we stand for.

MISSION STATEMENTTo be an engineering-driven manufacturing company relying on the commitment, creativity and experience of its employees.To exceed our customers’ expectations in quality, delivery and cost, through continuous improvement and customer interaction.To establish a partnership rather than to be a supplier in providing turnkey solutions for precast and on-site formwork issues.To create a high level of “Design For Manufacturability” in order to optimise production processesTo produce, sell and rent state of the art modular shuttering systems with a service-based approach.

To turn every single project into a success by having the guts and the flexibility to have a different approach when needed.To guarantee good communication, short decision lines and perseverance in coping with customer requirements.

VISIONConstrux will grow further and become a fully vertically integrated company with 2 separate though intensely cooperating divisions.Construx Red is the on-site division which designs and manufactures special forms and moulds as well as 3 standard modular shuttering systems:

The 3 systems are complementary and meet various on-site requirements.Construx Red supplies these 3 shuttering systems in both rental and sales.Construx Blue is the precast division which designs and manufactures custom made formwork solutions for the precast industry.Construx Blue is above all the preferential partner of all precast companies for their moulds and other formwork devices.

STRATEGYConstrux will continue to invest in the expansion of its 3 existing premises in Belgium. First of all to secure their status as cornerstones of further growth and secondly to maximize their capability of supporting the integrated Construx strategy.Construx wishes to establish a worldwide network of partnerships to distribute its products and in particular the 3 modular on-site shuttering systems, Tricon, Mega and Conalu.Construx will look for acquisitions and endogenous growth to fulfil its ambition of becoming the Top Of Mind for precast and on-site formwork projects in Europe and abroad. The objective is an integrated design and manufacturing group of companies specialized in the development, production, installation and servicing of formwork.

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COMPANY HISTORY

2003

Founded as an engineering company.

2006

Joint-venture with “Constructie Demyttenaere” in Hulste to cope with the important missing link of in-house manufacturing facilities.

2007

Fast growth by realising state of the art solutions for formwork projects.Standard precast machinery has been optimised, the oddest concrete forms have been manufactured and challenging on-site projects have been brought to a good end.

2008

Move into the new premises in Genk.

2011

Launch of the Tricon

shuttering system, a rigid galvanised frame shuttering system, designed in Genk and manufactured in Hulste.Design and production of a new heavy-duty series of precast magnets.

2012

Acquisition of a 50% partnership in “Concrete Systems”, a regional sales and rental company which manufactures its own aluminium on-site shuttering system: Conalu. Concrete Systems fits perfectly in the Construx vision of full integration.

2013

Launch of the MEGA stainless steel shuttering system, an in-house designed and manufactured modular panel system for fair-faced concrete and high demanding jobs.

FACTS AND FIGURES

3 premises in Belgium: Genk, Hulste and Roeselare34.000m² total site surface area9.000m² total production surface area14 overhead cranes31 welding units26.000m² shuttering panels in rental1.000.000kg steel processed annually55 employees11 CAD-workstations with different systemsAll design in 3DIn-house production of all projectsDirectly represented in The Netherlands, France and the United Kingdom

Projects completed in 16 countries: Belgium, Luxemburg, The Netherlands, France, Germany, United Kingdom, Ireland, Switzerland, Poland, Turkmenistan, India, Sri Lanka, Nigeria, Saudi-Arabia and Equatorial-Guinea

Exhibiting at Matexpo (Belgium), Intermat (France), Betonvakdagen (The Netherlands), Bauma (Germany) en Concrete Show (United Kingdom)

MANUALLY MOVABLE FORMWORK SYSTEM FOR

PRECAST REINFORCED CONCRETE BEAMS.

This type of formwork system is also suitable for producing columns, lintels and other concrete components.

These battery moulds are composed of mobile steel panels with a 6mm steel sheeting on one or on both sides. There are also alternative sheetings: 18mm multiplex or 5mm stainless steel, both for exterior use. These movable panels are set and fit opposite to a fixed panel.

Customers can choose for a set-up with a fixed centre panel or a set-up with a fixed end panel.

The centre panel set-up offers 3 major advantages:

The option of selecting movable panels of various heights on the different sides of that centre panel

elements on both right-hand and left-hand side can easily be finished by hand

to work independently in each individual section

The fixed end panel set-up is the preferred choice if lack of space causes problems.

Customers can choose out of a wide variation lengths and heights.Frequently chosen dimensions are:

Lengths: 8m, 10m, 12m and 14m

Heights: 750mm, 1000mm and 1250mm

The movable panels are fitted onto 6m long, double steel

profiles. Each set of profiles is equipped with 5 feet. There are also other profile lengths available, for instance 4,5m or 8m. Two of these sets are equipped with flat steel guide rails for the panels to roll on.

The panels are equipped with a built-in mechanism to lock and

release them so they can be moved by hand.

At the bottom, the panels are closed by spindles. At the top, the panels are held into position by tie bars, they can be tied in an alternating way.

The top of the panels have a built-in wooden profile between both sheets, to easily fit triangular chamfers, etc...

Construx offers a wide range of bases, stop-ends, and height

adjustments.

Multibat

BEAMS / COLUMNS

6 -7

Multibat

BEAMS / COLUMNS

8 - 9

Project Multibat

FRANCE

THIS IS A SPECIAL MULTIBAT DESIGN FOR THE

FRENCH MARKET.

This manually movable formwork system is equipped with a fixed open central section, consisting of a working platform and 2 panels. This centre panel set-up has 1 intermediate panel and 1 end

panel on both sides.

This solid steel Multibat has been especially designed for exterior use, thus having a 5mm stainless steel sheeting. The special stainless steel alloy is magnetic in order to retain the benefit of working with magnets, which is common practice in a prefabrication environment.

The system complies with the stringent French safety

regulations, and therefore has built-in working platforms and holders for handrails.

BEAMS / COLUMNS

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Bibat

HYDRAULICALLY MOVABLE BATTERY MOULD

FOR PRECAST REINFORCED CONCRETE BEAMS

AND COLUMNS.

A standard configuration consists of 1 fixed centre panel and2 movable panels.

Depending on the application, the panels are equipped with a 6mm or 8mm steel sheeting.

The panels are opened and closed by hydraulic cylinders. The panels are therefore opened and locked without any manual

intervention.

There is also the possibility of installing additional movable intermediate panels in between the movable panels and the fixed centre panel. In that case, the additional panels will have to be locked into position with the use of tie bars.

Customer are free to choose any panel length or height, 13m and

14m panels and multiples (connected) of these are very popular.The stroke length of the cylinders combined with the height of the panels determines the maximum and minimum sections of the elements which can be made in such a battery mould.Heights of 1000mm and 1250mm are the most common.

The centre partition can either be open (with working platform)or closed.

To complete the range of Bibat battery moulds, there are a number of options available:

Fixed or modular panels, also available as removable and interchangeable partitionsRecesses to cast corbels together with the columns Hydraulically adjustable supports to adjust both the lateral position and the height and width of the bases Various manual systems for adjusting the base height

triangular chamfers at the top the panelsWorking platforms with access stairs at different levels

Bases can be manufactured in timber by the customer but these can also (for frequent use) be tailor-made in steel to suit the customer’s requirements.

BEAMS / COLUMNS

12 - 13

Bibat

BEAMS / COLUMNS

14 - 15

BELGIUM

THIS HYDRAULICALLY OPERATED BATTERY

MOULD IS ESPECIALLY DESIGNED TO CAST

HEAVY BEAMS OR MULTI-STOREY COLUMNS

WITH MULTIPLE CORBELS.

Its 22m length is suitable for producing very long or several short elements.

Both sections of the mould are equipped with 22m long hydraulically adjustable supports to adjust both the lateral

position and the height and width of the bases.

The overall height above the adjustable supports is 1215mm and the stroke length of the cylinders is 950mm.With a minimum width of 300mm, this gives a maximum net

section to be produced of almost 1200mm x 1200mm.

Both of the openings have 2 built-in recesses, which make it simple to set up the formwork for straight or sloping corbels.If the recesses are not intended to be used, they can be sealed off using perfectly fitting inserts.

In order to further increase the user-friendliness of this high and long battery mould, it is equipped with working platforms at

several levels.

Project Bibat

BEAMS / COLUMNS

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HYDRAULICALLY OPERATED BATTERY MOULD

FOR PRECAST REINFORCED CONCRETE BEAMS

OR COLUMNS, WHICH TOTALLY ELIMINATES THE

NEED FOR SEPARATE BASES.

This battery mould is ideal for precast elements with sizes

varying on a day to day basis.

There is a steel base located along both sides of a fixed work platform.On one side of this steel floor, a vertical panel can be moved

horizontally, against which a vertical panel can be hinged open

and moved vertically.Both movements, as well as maintaining the panels in a closed position, are fully hydraulic.Moving or locking the panels therefore does not require any

manual intervention.

This makes it very easy to set up the mould for a beam or a column without the need for timber bases.

Depending on the configuration, the base and the panels will be equipped with a 6mm or 8mm steel sheeting.

Ideally, the components will be cast in self-compacting concrete seen the vertical panel always stick out.

Triangular chamfers can be incorporated: on the outside of the fixed base, at the base of the horizontally moving panel and on top of the vertically moving panel.A magnetic triangular chamfer can be positioned against the horizontally moving panel in order to indicate where to finish the product.

There are several possible configurations, maximum dimensions of 1000mm x 1000mm and 1350mm x 1350mm, and 14m lengths are used on a regular basis.

Tribat

BEAMS / COLUMNS

18 - 1918 - 19

THE FIXED TABLES ARE CONSTRUCTED OF A

STEEL FRAME WITH A 8MM STEEL SHEETING.

The table consists of a flat and rigid structure and is suitable to cast floor slabs with a fair-faced finish

The maximum deflection guaranteed by Construx is 2mm over a

length of 3m.

The steel sheeting with maximum dimensions of 16m x 4m comes in 1 piece and is sandblasted and grinded on an automatic grinding machine in order to obtain a smooth finish.The level of smoothness depends on the customer’s requirements.

We can offer larger size tables, in which case the table will be manufactured in sections and the individual parts will be connected, welded and grinded in the precast factory.

The most popular table sizes are 13m x 4m and 14m x 4m.

The sides of the table can be equipped with fixed or adjustable

side forms. Full steel or timber side forms can be fitted onto the table by means of magnets.

In order to use the table’s full width, we supply individual supports along the length of the table, which can be used as an extra work surface if the side forms need to sit at the edge of the table.This means that a 4m wide table can be used to cast a 4m wide

structural component.

If the customer is not going to use self compacting concrete, the table can be equipped with vibrators, operating at either normal or high frequencies.In the latter case, a frequency converter will be used to adapt the vibration energy according to the shape and the sizes of the elements sitting on the table.

Vibration absorbers are fitted between the feet of the table and the factory floor.

Fixed table

FLOOR SLABS

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EQUATORIAL GUINEA

THIS FORMWORK TABLE IS CONCEIVED TO CAST

FILIGREE FLOORS ON SITE WHICH ARE GOING TO

BE USED AS SLABS FOR A BRIDGE.

Seen the size (10m x 5m), it has been decided to conceive the table as in 5 sections of 5m x 2m, which can be shipped to Africa in a normal container.

The various sections can be easily aligned and connected to each other after arrival on site.

One side of the table is equipped with a 100mm high straight

side form which is bolted onto the table.

The side forms dividing the table in sections are composed of a 60mm high straight part and a 40mm high detachable

chamfered part.

The movable side forms are fitted onto the table by means of magnets.

Project Fixed table

FLOOR SLABS

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TWO MAJOR ADVANTAGES OF THE USE OF

TILTING TABLES:

WITHOUT DAMAGING THE SIDES IF THE TABLE

IS TILTED INTO AN UPWARDS POSITION.

SAME WAY AS THEY ARE GOING TO BE

TRANSPORTED AND ERECTED ON SITE, THUS

IN A VERTICAL POSITION.

A tilting table consists of a rigid top structure which is fixed onto a tilting articulating base frame.

With the use of hydraulic cylinders, the top structure can be tilted up to 80°. By using multi-stroke cylinders there is no need for a recess in the floor.

The tilting top structure of the table consists of a steel frame with a 8mm steel sheeting. Which is suitable for casting wall panels with a fair-faced finish

The maximum deflection guaranteed by Construx is 2mm over a

length of 3m.

The steel sheeting with maximum dimensions of 16m x 4m comes in 1 piece and is sandblasted and grinded on an automatic grinding machine in order to obtain a smooth finish.The level of smoothness depends on the customer’s requirements.

We can offer larger size tables, in which case the table will be manufactured in sections and the individual parts will be connected, welded and grinded in the precast factory.

Tilting table

WALLS

24 - 25

The most popular table sizes are 13m x 4m and 14m x 4m.

The sides of the table can be equipped with fixed or adjustable

side forms. Full steel or timber side forms can be fitted onto the table by means of box-magnets.

In order to use the table’s full width, we supply individual supports along the length of the table, which can be used as an extra work surface if the side forms need to sit at the edge of the table.This means that a 4m wide table can be used to cast a 4m wide

elements.

If the customer is not going to use self compacting concrete, the table can be equipped with vibrators, operating at either normal or high frequencies.In the latter case, a frequency converter will be used to adapt the vibration energy according to the shape and the sizes of the elements sitting on the table.

In case vibrators are used, the top structure will be subdivided

into a top pallet and a tilting frame, with vibration absorbers fitted in between the two.

Tilting table

WALLS

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BELGIUM

TWO PRODUCTION HALLS, FITTED WITH A TOTAL OF

61 LARGE HYDRAULIC TILTING TABLES, DESIGNED

ESPECIALLY FOR THE PRODUCTION OF INDUSTRIAL

SOLID AND SANDWICH WALL PANELS WITH A FAIR-

FACED OR AN EXPOSED AGGREGATE FINISH.

60 tables measuring 13m x 4m

1 table measuring 16m x 4m

One of the two production halls is equipped with 3 rows of 6

tables and 3 rows of 7 tables.The other production hall is equipped with 1 row of 8 tables and 2 rows of 7 tables, including the one 16m long table.

Each table is equipped as follows:2 hydraulic cylinders (or 3 cylinders on the 16m long table)Adjustable (100mm to 300mm) side forms on 3 of the 4 sides of the table: on the bottom 13m long side and on both 4m sidesThe 13m long side form is divided in 2 equal parts of 6,5m

quick fixings at 140mm, 190mm and 250mm high

open hydraulically

8 individual supports along the top 13m long side of the table so 4m high walls can easily be castHigh frequency vibrators connected to the centrally located frequency converter

Heating underneath the tableInsulation on the floor and on the sides of the table

plug-in remote control to ensure safe workingcabling for the hydraulics, electricity, heating and controls is

concealed in covered gutters

integrated box magnets: straight forms as well as tongue

and groove forms

The hydraulic units and the frequency converters are set up at a central location in the production facilities.The wide open layout of the premises and the fact that there is no cabling in the way creates a large, free and open working space

around each table.This ensures that the supply of steel, concrete, side-forms, magnets, insulation and box-outs as well as the removal of rubbish can take place in a fast and safe manner.

Project Tilting tables

WALLS

28 - 29

IRELAND

THIS TILTING TABLE MOVES FROM ONE END OF

THE BUILDING TO THE OTHER END:

CONCRETE IS DONE IN A LOWER SECTION

DONE IN THE HIGHER PART WHICH IS AROUND

70M FURTHER

To achieve this, the tilting table is equipped with frequency controlled hydraulic motors so the table can move at variable speed.

The 75m long rails are fully recessed into the floor in order not to cause any inconvenience for the forklift trucks.Before tilting, the table must be secured to these rails with hydraulic clamps, this clamping is done automatically.

The steel sheeting of 16m x 4m came in 1 piece, was sandblasted and grinded on an automatic grinding machine in order to obtain a smooth finish.

The top 16m long side of the table has individual supports which can be used as an extra work surface if the side forms need to sit at the edge of the table.

The fully equipped table with overall dimensions of approximately 17m x 5m was transported from Hulste to the south of Ireland as one single unit.

The table is equipped with:

high frequency vibrators

frequency converter

Vibration absorbers between the upper structure and the tilting frame. Adjustable (100mm to 300mm) side forms on 3 of the 4 sides of the table: on the bottom 13m long side and on both 4m sides

The 13m long side form is divided in 2 equal parts of 6,5m

The electrical supply is provided by a conductor bar system fitted against the steel structure of the production hall.

Project Movable tilting table

WALLS

30 - 31

UNITED KINGDOM

THE EXTREMELY SMOOTH SURFACE OF THE

CONSTRUX TABLES IS PERFECT TO PRODUCE

ARCHITECTURAL WALL PANELS.

These 3 tilting tables are 14m long and 4m wide and with the use of 8 individual supports at the top long side of each table, 4m wide elements can be casted. These supports can be removed for transport reasons or to ensure that they do not cause any obstruction when not in use.

Each table comes with its own hydraulic group, fitted under the table.

The tables are equipped with machined plates, which can subsequently be fitted with vibrating motors. To be able to do so in the future, the tables are constructed with vibration absorbers between the upper structure and the tilting frame.

Each table is equipped with adjustable (100mm to 300mm) side

forms on the bottom 14m long side and on both 4m sides.

On one of the tables, the side forms have removable top-ups to make up to 400mm thick wall panels.

Project Tilting tables

WALLS

32 - 33

A SPINDLE TABLE IS A COMBINATION OF A

FIXED TABLE AND A MULTIBAT.

It is a multipurpose investment and provides a flexible method to cast walls and plinths as well beams and columns.

The idea behind a spindle table is to have panels sitting on a

table which is equipped with runners on its two short sides to enable the panels to roll along on wheels fitted on the outside of the panels.The panels are equipped with a built-in mechanism to lock and



At the bottom, the panels are hold into position by spindles. At the top, the panels are tied by tie bars, they can be tied in an alternating way.

Walls and plinths are cast directly onto the table, without using the movable panels in any way.Full steel or timber side forms can be fitted onto the table by means of box-magnets.

Beams and columns are cast in between the movable panels. In this set-up, a strip of plywood cut at the correct width serves as base and spacer.

Spindle table

WALLS / BEAMS

34 - 35

THE HIBAT “CARRIER” IS SUITABLE TO MAKE

PRECAST WALL PANELS AND PRODUCES A

FAIR-FACED FINISH ON BOTH SIDES OF THE

PANELS.

This vertical wall battery mould is a carriage-type system, and similarly to the Multibat, the panels run on floor-mounted tracks. Depending on the application, the panels will have a 8mm or 10mm steel sheeting.

The customer can select any height and length.The height usually varies between 2,4m and 3,5m and the length

between 6m and 9m.

The steel sheet always comes in 1 solid piece, and is sandblasted and grinded on an automatic grinding machine in order to obtain a smooth finish. The level of smoothness will depend on the customer’s requirements.

Moving the panels is done by electrical (with a winch or an electric motor) or hydraulic means (2 cylinders on the outer sides). These movable panels are set and fit opposite to a fixed panel.

Customers can choose out of 2 set-ups: A fixed centre panel combined with 2 movable end panels and a number of movable intermediate panels

fixed end panel combined with a movable end panel and a number of movable intermediate panels.


From the working platform of the centre panel, the precast elements on both right-hand and left-hand side can easily be finished by hand


The centre panel and the end panels are always equipped with a steel working platform with safety rails and access ladder.

There is no real limit to the number of intermediate panels, but in most cases a fixed centre panel will have 1 to 3 intermediate

panels on either side.

There are no ties going through the concrete.



adjustments.

Hibat C

WALLS

36 - 3736 - 37

THE “SUSPENDED” HIBAT IS A HIGH-

PERFORMANCE VERTICAL WALL BATTERY

MOULD CONCEIVED TO MAKE PRECAST WALL

PANELS AND IT PRODUCES A FAIR-FACED

FINISH ON BOTH SIDES OF THE PANELS.

It guarantees optimum user-friendliness due to the open and free

working space in between the “suspended” panels.

An additional advantage is that it offers the possibility of producing an enormous quantity of wall panels in a small

area, compared to the space a similar tilting table production would need.

The panels of this vertical wall battery mould run on an overhead track, as being suspended from that overhead steel structure.

All of the panels have a 10mm steel sheeting.This steel sheet always comes in 1 solid piece, and is sandblasted and grinded on an automatic grinding machine in order to obtain a smooth finish. The level of smoothness will depend on the customer’s requirements.

The customer can select any height and length.The height usually varies between 3m and 4m and the length between 7m and 13m.

There is only 1 typical set-up: a fixed centre panel with a number of movable intermediate panels and a movable end panel on either side.

The intermediate panels and the end panels move manually (chain drive) or by electrical means (plug-in with remote control).

The number of intermediate panels on either side of the centre panel will usually vary between 1 and 5.

From the integrated working platform of the centre panel, the precast elements on both right-hand and left-hand side can easily be finished by hand.The battery mould is as if it was divided into 2 sections, allowing to work independently in each individual section.

The end panels are also equipped with a steel working platform with safety rails and access ladder.

There are no ties going through the concrete.

At the bottom and at the top, the panels are closed by tie bars, they can be tied in an alternating way.


adjustments.

Hibat S

WALLS

38 - 39

Hibat S

WALLS

40 - 41

BELGIUM

THIS PRECAST FACILITY HAS 2 VERTICAL WALL

BATTERY MOULDS FOR PRODUCING FAIR-

FACED CONCRETE WALLS FOR HIGH-QUALITY

ARCHITECTURAL APPLICATIONS.

One wall battery mould is equipped with panels with overall dimensions of 7m x 3,25m.The other battery mould is a little larger and has panels with overall dimensions of 8m x 3,5m. The smallest battery mould is equipped with 2 movable

intermediate panels and 1 movable end panel on either side

of the fixed centre panel with integrated working platform.

These panels can be moved manually by means of a chain drive.This set-up creates 6 pockets to cast wall panels. Half of these pockets are equipped with a special adjustment system

to position the side forms and the bases with the required precision.

The other 3 openings are fitted with box-magnets and the necessary accessories to maintain the side forms in position. The largest battery mould is equipped with 1 movable

intermediate panel and 1 movable end panel on either side of

the fixed centre panel with integrated working platform.These panels are moved by means of an electrical plug-in

system and a remote control. This set-up creates 4 pockets to cast wall panels.

All of these pockets are equipped with a special adjustment system

to position the side forms and the bases with the required precision.If required, the large battery mould can be extended to include up to 8 pockets.

Project Hibat S

WALLS

42 - 43

INDIA

THIS PRECAST FACILITY HAS A HIBAT S TO

PRODUCE BOTH INTERIOR AND EXTERIOR

WALLS FOR SOCIAL HOUSING.

Casting wall panels in a wall battery mould is the ideal solution given the limited number of rebar and inserts required and the low complexity of the wall panels. Furthermore, this job is also highly repetitive, so the cost-saving achieved by producing 2 fair-faced finished sides should certainly not be underestimated.

The vertical wall battery mould consists of an overhead track together with following components:

1 fixed centre panel with integrated working platform

2 x 5 movable intermediate panels

2 x 1 movable end panel

The panels are 12m long and 3,25m high, which offers a total gross capacity of 468m² walls per day.

Due to the high repetition factor, all the panels are equipped with fixed floors and stop-ends to ensure that the processes are easy, fast and error-free.

Project Hibat S

WALLS

44 - 45

THIS FORMWORK IS SUITABLE FOR PRODUCING

STAIRS UPSIDE DOWN (STEPS FACING

DOWNWARDS).

A hydraulic unit operates 2 horizontal cylinders in order to adjust the distance in between the individual steps.The same hydraulic unit also controls 2 vertical cylinders, which adjust the angle between the steps.

Consequently, both going and rise are hydraulically

controlled.

Usually, the width of the stair mould is 1,5m but this can be wider, e.g. 2m or 2,5m.In the larger moulds 2 stairs can be cast next to each other.

Customers can choose any number of steps, but the number usually varies between 16 and 24. Long moulds with 20 steps or more can be used to cast 2 flights of stairs with a limited number of steps simultaneously.

One side of the stair mould is equipped with a height-adjustable side panel. As a result of this height adjustment, the steps can vary in thickness between 120mm and 250mm. For wide stair moulds, an extra adjustable side panel on the other side is an appropriate option.

The stair mould includes 2 sets of landing equipment (top and

bottom).

The panel for the bottom landing is constructed as an extended

STAIRS

Fully hydraulically adjustable horizontal stair mould

46 - 47

first step element. The position of the bottom landing panel can be hydraulically adjusted.

The panel for the top landing sits on a carriage and can be inserted at every position after removing a step.

If the top landing carriage is set up at the rear of the mould, it will be linked to the last axle, thus travelling back and forth when the goings and risers are hydraulically adjusted. The angle of the top landing panel can be controlled manually with great precision by means of 2 manual spindles.

In order to work safely and easily, the system includes a fixed

working platform on the non-tilting side. There is also the option of equipping the system with an extra removable working

platform on the tilting side.

The entire stair mould can be equipped with a hydraulic tilting

device to facilitate the installation of the reinforcement and the removal of the concrete stairs.

The steps can feature several designs:

Straight steps

Steps with cut-back

Steps with cut-back and nose

In order to produce these 3 different features, the step elements are designed with a support plate which falls back 18mm, incorporating timber blocks and magnets. These can be used to fit 18mm plywood strips or 3mm metal

plates onto which 15mm plywood strips are screwed.

The steps with cut-back and nose can be produced by using triangular magnetic chamfers which can overlap an opening of 30mm.

As a standard feature, the goings are adjustable between 200mm

and 320mm and the rises are adjustable between 150mm and

200mm.

The use of a hydraulic hand pump is a budget-friendly

alternative to this fully hydraulically adjustable stair mould.

Fully hydraulically adjustable horizontal stair mould

STAIRS

48 - 49

BELGIUM

THIS ADJUSTABLE STAIR MOULD IS 1500MM

WIDE AND FEATURES 24 STEPS, WHICH MEANS

THAT IT CAN BE USED TO POUR SEVERAL

SHORTER FLIGHTS AT THE SAME TIME.

The goings are adjustable between 200mm and 320mm and the rises are adjustable between 150mm and 200mm.

The moulds are equipped with a hydraulically adjustable bottom

landing panel and a top landing panel sitting on a carriage.In addition, the mould comes with an extra top landing panel that can be fitted anywhere against a step, without the need to remove any steps.

The step elements are designed with a support plate which falls

back 18mm, incorporating timber blocks and magnets. These can be used to fit 18mm plywood strips or 3mm metal

plates onto which 15mm plywood strips are screwed.2 sets of 24n° of these 3mm metal plates have been provided.

The mould is equipped with a hydraulic tilting device and an extra collapsible working platform on the non-tilting side of the mould.

Project Fully hydraulically adjustable horizontal stair mould

STAIRS

50 - 51

STAIRS

Project Fully hydraulically adjustable horizontal stair moulds

SWITZERLAND

IN THIS PRECAST FACILITY, THE INVESTMENT

INVOLVED 3 IDENTICAL, FULLY HYDRAULICALLY

ADJUSTABLE STAIR MOULDS WITH A WIDTH OF

1500MM AND EACH EQUIPPED WITH 20 STEPS.

The goings are adjustable between 200mm and 320mm and the rises are adjustable between 150mm and 200mm.

The moulds are equipped with a hydraulically adjustable bottom

landing panel and a top landing panel sitting on a carriage.

The step elements are designed with a support plate which falls

back 18mm, incorporating timber blocks and magnets. These can be used to fit 18mm plywood strips or 3mm metal

plates onto which 15mm plywood strips are screwed.

All 3 moulds are equipped with a hydraulic tilting device.

52 - 53

Project Hydraulically adjustable horizontal stair moulds with hand pump

POLAND

THESE 2 MOULDS ARE ONLY SUITABLE FOR

PRODUCING STAIRCASES FEATURING STRAIGHT

STEPS.

To do so, a simple version of the fully adjustable mould is used: a hydraulic unit operates 2 horizontal cylinders in order to adjust the distance in between the individual steps.

The angle between the individual steps is not adjustable, the rises are made out of plywood strips which need to be cut to measure.

The step components can easily be tilted backwards to fit the plywood strips onto the support plates. Which means that this type of mould has steel goings and timber rises.

Both of the moulds are non-tilting and only feature a bottom landing panel.

One of the moulds has 12 steps and the other has 18 steps.

STAIRS

Vertical stair mould with inserts

THIS STAIR MOULD IS A SIDE-CAST TYPE FOR

STRAIGHT FLIGHTS.

The stair mould has 1 fixed centre panel and 2 movable

outside panels, all 3 with working platforms.These panels roll on a full steel base plate.

Customers can choose any panel length, but the panels usually vary between 6m and 9m.The most common height is 1500mm.

Both sides of the centre panel have an open structure, which can be used as a base to fix steel or timber inserts.

The full steel outside panels have straight or triangular rubber sealants at the bottom and can be slightly lifted and opened by

hand.

Depending on the length of the stair mould, both pockets of the

mould can be used to cast 1 or 2 flights per pocket per day.

There is also the option of casting a bottom landing or top

landing per flight, up to a length of 1500 mm.Please note that stairs with both bottom and top landing are not feasible.

The making of landings requires:

4 adjustable bottom landing panels

54 - 55

THIS IS A FULLY EQUIPPED SIDE-CAST STAIR

MOULD, INCLUDING ADJUSTABLE LANDING

PANELS, LANDING INSERTS AND ADDITIONAL

TABLES.

The base of the mould is 9m in length and the overall length (including landing panels) is 12m.

Thanks to its long base and in view of the fact that the panels are 1500mm high on one side and 1800mm high on the other side, the stair mould is easily adaptable for producing stairs in a wide selection of widths and lengths.

In order to easily gain access to the fixed centre panel, access stairs have been fitted at both ends. These stairs can easily

be removed if they are in the way for producing a flight with a bottom landing.

Inserts of all different features have been made to fit in this mould, as there are:

Straight steps

Steps with cut-back

Steps with cut-back and nose

Most of these inserts include a landing insert.

Project Vertical stair mould with inserts

STAIRS

FRANCE

56 - 57

STAIRS

Combicaster

THIS TYPE OF STAIR MOULD IS SUITABLE FOR

PRODUCING WINDING STAIRS IN A TOP-DOWN

CONCEPT.

The mould consists of a number of panels, which can be used in either direction.

On one side, they feature a straight timber profile on which strips

of 18mm plywood can be nailed. On the other side they feature a steel cut-back which requires the use of magnetic triangular chamfers.

The goings are adjustable between 165mm and 195mm.The magnetic chamfers can overlap a maximum opening of 30mm.

The panels must be stacked onto each other, bolted together and propped.

A standard package consists of:

1 base panel 1800mm wide x 1500mm deep

All panels can be used either in a straight line, in a left-hand

turn or in a right-hand turn.

This combined with the fact that the panels can be used both for straight steps and for cut-back steps ensures that the Combicaster is an extremely profitable and highly versatile

winding stair mould.

As the panels are so wide, there is sufficient room to work next to the stairs on the panels, and this means that all actions can be completed safely and rapidly.

58 - 5958 - 59

BELGIUM

THESE 3 COMPLETE SETS, INCLUDING

PANELS AND ACCESSORIES ARE FULLY

INTERCHANGEABLE. THE MAIN ADVANTAGE IS

THAT ALL THE PANELS ARE SIMILAR.

The Combicaster does not have any left-hand or right-hand panels or separate panels for straight steps and for cut-back steps. The dimensions are the only difference: the standard panels are

1800mm wide and the corner panels are 2200mm wide. However, the corner panels can also be used as standard

panels and the standard panels can also be used in the

corners, although this will reduce the working area.

By purchasing several sets, winding stairs can be produced in the most wide-ranging shapes without any panels being unused and left aside. The investment therefore pays for itself in no time.

Project Combicaster

STAIRS

60 - 61

Lifting, tilting, transporting and storage of concrete and concrete elements

ACCESSORIES FOR HANDLING AND

TRANSPORTING CONCRETE AND PRECAST

CONCRETE ELEMENTS:

Spreader beams for transport and installation of precast and pre-stressed, concrete elements, such as beams and columns

Hoisting gear for transport and installation of precast concrete elements, such as tanks, lift shafts, staircases and box-culverts

Tilt hoists for installing precast concrete pillars on site.

Tilting equipment to turn over concrete elements

Racks for storage and transport of precast concrete wall panels

Concrete buckets for transporting concrete in a precast hall.

concrete pumps, placing booms

Storage for aggregates and concrete

The equipment listed above is developed by Construx and CE

certified.

CONCRETE

62 - 63

Project Concrete pump

ENGINEERING, AUTOMATION AND INSTALLATION

OF A CONCRETE PUMP WITH PLACING BOOM

IN AN EXISTING CIRCULATION PLANT FOR

PRESTRESSED BEAMS.

The installation consists of the following components:

Supply shoot for filling the pump by means of a concrete bucket

buffer tank with electronic detectionStatic concrete pump with 55kW electric motor Hydraulic movement of the pump for cleaning purposesConcrete transport from pump to boom over 50mHydraulically controlled placing boom, length 14mRemote control for buffer tank, concrete pump and placing boom, all in one

FRANCE

CONCRETE

64 - 65

Project Tilting station

DOUBLE HYDRAULIC TILTING STATION TO

ROTATE CONCRETE PUMP SUMPS, THAT ARE

CAST UPSIDE DOWN, BY 180°.

The sumps can be square or round in shape (possibly with several flat sides).

Maximum diameter of concrete elements: 1600mm

Height of elements: minimum 800mm – maximum 2700mm

Maximum weight of elements: 7,5T

The tilting station consists of 2 independent hydraulically

controlled tilting mechanisms, of which the first is fixed to a base frame and the second can be moved hydraulically toward the first one.

BELGIUM

Formwork for tanks, box culverts, shafts and cores

FIXED OR ADJUSTABLE FORMWORK FOR

VARIOUS TYPES OF PRECAST ROUND- AND

SQUARE-SHAPED FORMS

The formwork can have a simple or complex design, depending on whether or not it needs to be adjustable and how many components need to be produced.

In most cases, there are no ties through the concrete element. However, when working with small modular panels, this is inevitable.

Please find below a brief overview of the various types of precast

elements for which this type of formwork is designed:

Lift shafts

Staircases

Transformer housings and electricity substations

Control buildings

Pipes

Collectors

Box culverts

Pits

Basements

Water tanks

Septic tanks

Certain types of formwork have to be manually opened, closed and fixed, whereas others can be operated fully hydraulically.

In most cases, the precast elements are cast with self-

compacting concrete. Otherwise vibrators can be provided, either with or without a frequency converter.

TANKS / BOX CULVERTS / SHAFTS / CORES

66 - 67

Formwork for tanks, box culverts, shafts and cores


68 -69

BELGIUM

The rainwater tanks are oval and rectangular in shape.

All inner moulds are slightly conical, and the oval moulds are also hydraulically shrinkable. The outer oval moulds consist of 2 halves and the outer

rectangular moulds consist of 2 L-shaped sections. To release the tank, the outer mould is first opened hydraulically, after which the hydraulic system pushes the floor upwards. Overview of the types of tanks for which moulds have been purchased: Oval tank 15000L

1500mm

1500mm

The lubrication pits are U-shaped.

They are 4850mm long, 2100mm wide and 1400mm high. The mould for the lubrication pits has a double set of bases to speed up the process and to ensure casting concrete on a daily basis. The bases with the pit on top are pulled out by means of a winch. The outer mould opens hydraulically and the inner mould

shrinks hydraulically.Forms for a special series are included, these serve to make connecting modules, front parts, end parts and intermediate

elements.

The basements are not conical but fully rectangular with

sharp 90° angles in between the walls and between the walls

and the floor.

All inner moulds shrink hydraulically and all outer moulds open manually. The complete set consists of 1 fixed and 2 adjustable (modular) moulds: Fixed mould: L 3240mm x B 2540mm x H 2100mm

2100 or 3000mm

2100 or 3000mm

Fixed and adjustable moulds for rainwater tanks, lubrication pits and basements


70 - 71

BELGIUM

THIS WORK INVOLVES PRECAST 2.5M LONG

WATER DRAINAGE CULVERTS FOR TO BE

INSTALLED ALONG THE RAILWAY TRACKS OF

THE REGIONAL EXPRESS NETWORK IN THE

BRUSSELS AREA.

In total, 12 complete moulds are installed in order to manufacture all the different sizes of culverts and special components. The box culverts stand straight up during the whole process.

When releasing, the culverts are directly rotated 90° in the air with the aid of 2 overhead cranes, after which they are stored on their side as how they are going to be transported and installed. The outer moulds comes in 2, and in 3 sections, each section can be moved individually. Moving the sections is done by hand because there is only a small force required to move the heavy components.The inner moulds are completely straight and rigid and do not shrink. A few hours after casting the concrete, the inner moulds are removed by pulling them up out of the concrete culvert, precisely when the concrete is sufficiently set and does not stick to the mould too much yet.

The outer moulds are opened at night, after which the culverts can be taken out. The advantage of this process is that it saves a great deal of

time. After all, as soon as the inner core has been taken out, this core can again be prepared and in the morning it will only take a few hours before the 12 moulds are ready to be cast again.

The use of self-compacting concrete combined with straight, rigid and perfectly sealed (rubber joints) moulds produces magnificent, smooth concrete elements without any defects.The inserts for the tongue and groove connections fit so well that, afterwards, the rubber seal can be positioned onto the concrete lip without any problem.

Given the fact that these culvert moulds are in use for extended periods of time, each mould is equipped with a steel working platform around its entire circumference, complete with safety rails and an access ladder.

Project Formwork for box culverts


72 - 73

GERMANY

A CONCRETE PRECAST SYSTEM TO

MANUFACTURE COMPLETE CONTROL PODS,

INCLUDING FLOOR SLAB, WALLS AND ROOF.

First, the walls and the roof are cast as one single unit.The following day, this unit is taken out and positioned onto a table, after which the floor slab is cast.

The pod is made straight up so there is no need to turn the

elements and fixing the steel and fitting the accessories is made easy.

Before the elements are taken out, a number of components (anchor rails, box-outs and door openings) are released, after which the outer mould can be opened.

The inner mould shrinks hydraulically and has a wedge system to sufficiently release the precast element.

The bases feature a discontinuous pattern of openings to let

the rebar stick through. These openings are sealed or released in 1 single movement by means of system with small rubber plates in steel holders.

After the first phase, the entire unit (walls + roof) only needs to be lifted by 500mm, after which it is moved and fit onto the formwork table.

The unit is positioned onto 4 concrete feet, cast in the 1st phase. These feet act as spacers.

The table has built-in side forms and box-outs and is a perfect fit for the concrete unit coming from the 1st phase.

Both the table as well as the formwork mould for the walls and the roof are equipped with vibrators. However, the customer can also use self-compacting concrete given that all the joints are equipped with rubber sealants.

Project Mould for wind turbine control pods


74 - 75

BELGIUM

THIS FORMWORK SYSTEM IS BUILD UP OF FULL

STEEL SHUTTERING PANELS: STEEL FRAME +

STEEL SHEETING.

The entire structure is installed onto a frame adjustable to a maximum section of 6m x 3,5m. The smallest inner dimension is 1200mm x 1200mm.

The height of both the inner and the outer core is built up from 3 panels of 1200mm, i.e. the maximum height of the complete precast piece is 3600mm.

The bases are also modular and their height is adjustable, so that finishing the concrete is done at the top of the panels.

The outer formwork consists of 2 L-shapes and is equipped with a working platform around its circumference. The inner formwork is equipped with shrinking corner pieces.

The inner and outer corner pieces correspond to each other at wall thicknesses of 140mm and 200mm. By using adjustable panels both in the inner and outer formwork, the width and length are adjustable in steps of 100mm.

The various widths available are: 100mm, 200mm, 300mm,

400mm, 600mm, 800mm, 1000mm, 1200mm and 1400mm.

Project Modular formwork for staircases and lift shafts


76 - 77

BELGIUM

VARIOUS MOULDS FOR SUBSTATIONS FOR THE

BELGIAN MARKET.

Type 1: Single substation with fixed dimensions:

The floor is cast first, the next day the walls are cast on top.

The inner mould is mechanically shrinking and the outer mould must be removed with the crane.

Type 2: Tower substation consisting of 2 parts:

Dimensions substructure: Height 2535mm

Dimensions upper structure: Height 1680mm

Both the substructure and the upper structure are cast upside

down, and turned 180° the next day using a tilting frame.

Type 3: Large medium voltage substation

Height 2500mm

wedge system in 2 corners to enable releasing.

Project Moulds for substations


78 - 79

RETAINING WALLS / GUTTERS

Formwork for Retaining Walls and Gutters

CONSTRUX OFFERS A WIDE RANGE OF

SOLUTIONS FOR CASTING CONCRETE RETAINING

WALLS AND GUTTERS. THESE ARE USUALLY

CAST UPSIDE DOWN AND HAVE TO BE ROTATED

BY 180°.

The formwork may vary in design, but their concept remains the same.After all, for this type of formwork, the emphasis is on volume.

The main aim is to produce as many identical pieces as

possible, and the speed of casting and releasing is essential.

Please find below an overview of applications:

L-shaped retaining walls

T-shaped retaining walls

U-shaped retaining walls

U-shaped cable gutters, with or without feet

U-shaped drains, with or without drainage holes

The moulds can be manufactured so as they are adjustable, in order to manufacture the same type in various sizes.

Hydraulic opening and closing is recommended for larger size components.

80 - 81

BELGIUM

PRECAST OF L- AND U-SHAPED RETAINING

WALLS IN 3 SEPARATE FORMWORK MOULDS.

All the moulds are designed to cast concrete elements of different

heights, each requiring a different base. If necessary, additional feet can also be cast.

Details for the 3 moulds:

U-sections, H 3m x L 2m x W 1,5m, capacity 2 x 2m’ or 1 x 4m’

The formwork for the L-sections is designed as a double mould, with 2 identical moulds positioned back to back.

Project Formwork for Retaining walls

RETAINING WALLS / GUTTERS

82 -83

PRESTRESSING

Formwork moulds and complete installations for prestressed elements

CONSTRUX PROVIDES THE ENGINEERING,

MANUFACTURES AND INSTALLS PRESTRESSING

BEDS AND MOULDS.

Below an overview of the applications:

IV beams for industrial buildingsI-beams for bridgesDouble T-beams for floors in buildingsSolid slab and hollow core floors for floors in buildingsTreble T-beams for roofs of industrial buildingsRailway sleepers and turn-out sleepersCrane rail sleepers for portal cranes

84 - 85

BELGIUM

STEEL BEDS TO MAKE PRESTRESSED

ELEMENTS.

A total of 4 beds with each an overall length of 86m and a net length of 80m.

The prestressing beds have a overall width of 1500mm and can be used to make elements with a maximum width of 1000mm.

Three 25T anchors are fixed at each end.

Each bed can be loaded to a maximum of 600T at 500mm

eccentricity.

Each hydraulic installation consists of two 300T cylinders and two 150T cylinders, all with a 200mm stroke.

Project Prestressing beds

PRESTRESSING

86 - 87

UNITED KINGDOM

LONGITUDINALLY PRESTRESSED WALL PANELS

WITH A MAXIMUM LENGTH OF 10M.

They are post tensioned transversely after installation.

The wall elements are made on carrousel beds.

Construx is supplying a total of 5 casting beds:

4 beds for standard elements

Gross bed length: 12,5m

Net bed length: 10,5m

Element width: 2,4m

Prestressing per bed: 300T

The angles of the side forms are adjustable from 17° (tank with 11 panels, 7,7m diameter) to 2° (tank with 90 panels, 68,59m diameter). Adjustment is done manually with four bolts per side.

Once adjusted, the supports can be opened and closed

hydraulically with a hand pump.

Project Prestressed tank elements

PRESTRESSING

88 - 89

Moulds for railway sleepers

CONSTRUX PROVIDES THE ENGINEERING AND

PRODUCTION OF SLEEPER MOULDS AND THEIR

PRESTRESSING FRAMES FOR CARROUSELS AND

LONG-LINE SYSTEMS.

There are 2 types of moulds:

Tension-rigid moulds in which the prestressing force is directly transferred to the form, for example 4-gang moulds for use in a carrouselNon tension-rigid moulds in which the prestressing forces are taken by an independent bed or frame, for example in a long line configuration

PRESTRESSING

90 - 91

UNITED KINGDOM

PRESTRESSED CRANE RAIL SLEEPERS WITH

A LENGTH OF 1500MM, PRODUCED IN AN

EXISTING CARROUSEL SYSTEM.

There are 4 beds with a length of 12,5m, each equipped with 42

single forms: 7 rows of 6 sleepers next to each other.

The moulds for the sleepers have an opening for the Pandrol fastening and are sprung mounted to take up the prestressing force after releasing.

Each crane rail sleeper is prestressed with 3 wires of 19T each.

Each bed has two 150T hydraulic jacks.

The end forms consist of two parts to be able to put in the wires.

The forms are removed with a six-gang lifting and tilting frame.

Project Sleeper moulds, London Gateway

PRESTRESSING

92 - 93

Retaining wall blocks

CONSTRUX PRODUCES VARIOUS TYPES OF

MOULDS FOR RETAINING WALL BLOCKS.

These are used as single forms at batching and precast plants to process residual concrete, and sometimes also in serial

production to cast large quantities of stacking blocks.

A common dimension is 1800mm x 600mm x 600mm.

To be able to stack the blocks and to be able to make corners, the length must always be a multiple of the width.

The tops of the blocks have studs which correspond with recesses underneath the blocks.

BLOCKS

94 - 95

SPECIAL FORMS

96 - 97

GREEN BARRIER RETAINING WALLS FOR

THE REGIONAL EXPRESS NETWORK IN THE

BRUSSELS AREA.

Consisting of vertical stands with corbels on both sides upon which concrete casings can be placed.

Construx is providing the following forms:

1 hydraulically opening mould, length 10m, for the vertical stands

These mould can be used to cast stands with heights varying

from 2,8m to 10m in height, in 900mm increments

2 hydraulically opening mould, length 10m, for 2 concrete casings per mould

Casings with lengths of 4450mm and 3850mm can be combined in both moulds

1 hydraulic tilting device to place the vertical stands in an upright position on site1 tilting frame to fit the vertical supports on site

Project Retaining walls

SPECIAL FORMS

BELGIUM

98 - 99

Project Viaduct elements

VIADUCT ELEMENTS FOR THE REGIONAL

EXPRESS NETWORK IN THE BRUSSELS AREA.

There are two types of elements: short and long, for single and double railway track expansions.

The large elements are 10,53m x 3,39m and weigh 29T.

The forms are removed as follows:

Opening the side panels hydraulically

Reversing of the anchors manually

Pushing the elements up hydraulically (6 hydraulic

cylinders)

BELGIUM

SPECIAL FORMS

100 - 101

Project Prison cell walls

INTERIOR WALLS OF PRISON CELLS THAT

ARE CALLED “CACTUS WALLS” DUE TO THEIR

SPECIFIC SHAPE.

These are concrete partition walls that must have a fair-faced

on both sides.This requires them to be cast upright.

Construx has completed 2 projects for this product, for 2

different customers:

Project 1: 3 complete moulds, fixed height, hydraulic

opening and closing

Project 2: 5 complete moulds, adjustable height, manual

opening and closing

The forms are made up of a frame with base, rails and a fixed panel. The 3 other panels are opened and closed manually or

hydraulically, and are thus pulled against the ground.

UNITED KINGDOM

SPECIAL FORMS

Project Tunnel elements

A TOTAL OF 5 CURVED MOULDS MOUNTED ON

EXISTING TILTING TABLES.

Curved tunnel elements for a project in Norway are made on these tables.Cast with dry concrete and finished with a curved vibrating

screed and vibrators on the tables.

After curing, the elements are tilted and transported vertically.

NORWAY

102 - 103

Project Motorway barriers

VARIOUS MOULDS FOR PRECAST CONCRETE

MOTORWAY BARRIERS.

Type 1: mould for 2 elements behind each other, with a length

of 1m

Type 2: mould for 2 elements next to each other, with a length

of 6m

BELGIUM

TURKMENISTAN

MOULDS FOR CORNICES TO BE INSTALLED

ON THE PRESIDENTIAL RESIDENCE OF

TURKMENISTAN.

A total of 13 moulds, each mould has extra partitions to be able to make mitred cornices. This mitring is possible in two directions and is also possible at angles other than 45°.

Project Cornices

SPECIAL FORMS

104 - 105

SPECIAL FORMS

Project Burial vaults

VARIOUS MOULDS FOR SINGLE (1000KG) AND

DOUBLE (1800KG) PRECAST CONCRETE BURIAL

VAULTS.

The burial vaults are cast upside down.The next day the exterior mould is removed together with the

concrete vault and rotated 180° after which they are put down and the outer form is removed.

The inner form contains 2 manual mechanical valves to ease the process of stripping.

The full set consists of:

10 internal moulds for double burial vaults

20 external moulds for double burial vaults

5 internal moulds for single burial vaults

10 external moulds for single burial vaults

1 electric tilting unit to turn the vaults 180°

BELGIUM

106 - 107

Project Façade elements

BELGIUM

THESE FAÇADE ELEMENTS ARE SANDWICH

PANELS AND ARE ALSO PRODUCED AS SUCH:

flushed with white mortar

The standard elements weigh 15,5T and measure 7,2m by 3,66m

Project KASC

ENGINEERING AND PRODUCTION OF MOULDS

FOR PRECAST CONCRETE ELEMENTS OF THE

KING ABDULLAH SPORTS CITY IN JEDDAH.

Production drawings for the raker beams and the terraces were made to allow the customer to produce the moulds on site in Saudi-Arabia

A double terrace mould was produced to serve as a model for the moulds to be made on site.

Saudi-Arabia

SPECIAL FORMS

108 - 109

Project Façade elements

BELGIUM

X AND V-SHAPED NON-STRUCTURAL ELEMENTS

IN ARCHITECTONIC CONCRETE FOR THE FAÇADE

OF A SCHOOL BUILDING IN ANTWERP.

All the V-shaped elements can be seen as half X’s. angle between the

legs of the X and V-forms varies. There is a total of 6 different variations of the 2 shapes.

The following forms were supplied for this purpose:7 base frames

3 fixed moulds in which only 1 specific type can be made4 adjustable moulds in which you are able to make 2 different types 11 bases, one or more per type7 sets of 4 stop ends

Extra stop ends to be able to make V-elements

REDACTION

December 2007

C.F.Structures Ltd. and Construx b.v.b.a. : a strong partnership

C.F.Structures Ltd. is a medium-sized construction company located in Dublin and has been erecting residential and industrial buildings for over 25 years. Their core business is on-site concrete works as a subcontractor for some of the major Irish building companies.

Due to the economical boom in Ireland, there has been an enormous requirement for precast concrete elements in the last decade. For the last couple of years the nationwide capacity was not able to catch up with the demand.

Importing precast elements from abroad was the only solution. Confronted with increasing difficulties to get precast slabs on site on time, Tim McNulty the owner of C.F.Structures Ltd. decided to start making them in his own premises. Construx b.v.b.a. a Belgian based manufacturer of shuttering and precast machinery helped him out.

Extremely compact but very profitable circulation plant

The complete carrousel system runs in an area of 84m x 12m which is an extremely tight setup.

The size of the 20 steel pallets is 12,5m x 2,4m and they have 80mm high fixed tapered side forms on both the 12,5m long sides. On a pallet with 3 magnetic 2,4m long side shutters 2 filigree slabs with a total length of 12,3m can be poured. The pallets are transported by means of rollers and driving wheels in longitudinal direction. The transversal movement is done by pairs of cross transport wagons.

The hydraulic lift is situated in between two storage racks with 9 levels each, an extra buffer position is situated underneath each rack. At a later stage the two storage racks can be equipped as curing chambers allow working in a double shift system. One position in the circulating system has vibrating wheelyokes instead of rollers. In the future another position can eventually be changed into a second vibration station because the concrete placing boom has a 10m radius.

In total the circulating plant consists of no more than 9 positions, including the lift and the two storage racks. Although it still remains a very flexible system: both the lift and the vibrating station can be reached from 3 positions. Seen that demoulding, lifting the slabs, cleaning and oiling the pallets, placing the side forms, the boxouts and the steel reinforcement takes place in only 3 positions, the operator has 4 buffer positions to go to when needed.

PUMPING CONCRETE IN A NEW PALLET CIRCULATION

PLANT AT C.F.STRUCTURES LTD. IN SUMMERHILL, IRELANDIn order to meet specific requirements

such as minimal labour attendance,

small existing premises, foolproof setup

and guaranteed daily output, Construx

b.v.b.a. installed a very compact precast

production facility for filligree slabs. The

customer, C.F.Structures Ltd., being a

building contractor without any precast

production background, insisted on a

quick and above all profitable concept.

The Construx b.v.b.a. engineers conceived

a carrousel plant with a maximum output

of 590m2 slabs per shift, only requiring a

staff of 4 to 5 people. The Summerhill pallet

circuit system stands out because of the

use of a concrete pump with placing boom

(both remote controlled) and a digitally

controlled hydraulic pallet lifting system

with an accuracy of 0,1mm.

110 - 111

Pumping concrete in the plant by

means of a stationary pump and

a placing boom

At the moment there is no batching plant on the premises so all concrete is brought in by means of truck mixers. The initial idea of a shuttle system to bring the concrete from the ready-mix truck to a bucket spreader was quickly abandoned because of the complexity to build this type of installation in such a small area. In previous installations Construx b.v.b.a. already tried to convince some customers to go for the option of using a stationary concrete pump in combination with a placing boom to

pour concrete in a quick and cost-effective way, but being the guinea pig never seemed to be an attractive idea for the clients.

For Tim McNulty, on the contrary, using a concrete pump almost seemed as the only way to guarantee a daily output of 20 pallets. Another very important reason for him to choose for the pump was the fact that he controlled the complete procedure: making precast slabs, installing those slabs on his own sites and pouring the top layer on site himself.

Thus there was no real need for differences in thickness, 80mm would be perfect for all the

slabs whatever the overall thickness of each individual slab finally would be. The pump used is an OLIN 1545 S-valve type which has an output of approximately 25m3 per hour. As a subcontractor for Construx b.v.b.a., Reginald Maes the Managing Director of M.R.C. Betontechniek b.v.b.a. in Belgium installed the American originated pump with a sound roofing and an automatic greaser.

The pump sits in a shed right outside the building at a distance of only 1m from the placing boom inside the building. An electrical frequency controlled motor is mounted on the first articulation of the ACME placing boom in order to rotate the first leg of the boom.

By means of two remote controls (one on the pump and the other on the electrical motor) one person can take care of the whole pouring process whilst moving by hand the end of the second leg of the placing boom. On the outside the truck driver controls the feeding of the concrete into the hopper on the pump which has a capacity of 220L.

In case of any delay in the concreting while there is still concrete inside the pump or the placing boom, the end of the second leg of the boom can be connected to a tube, so the concrete can be pumped back into the hopper outside. The concrete can be pumped around in the system in order to avoid intermediate cleaning.

REDACTION

Digitally controlled hydraulic pallet lifting system with a 0,1mm accuracy

Another critical element in the pallet circulation plant is the lift. The lack of working space in the premises resulted in a semiautomated carrousel controlled by a PLC which was programmed by the Construx b.v.b.a. engineering staff. A system with completely automated movements would simply be too dangerous to operate, so every single change of position of a pallet has to be initiated by an operator. There was a real chance on creating

a bottleneck situation on the lift. To avoid such a risk Construx b.v.b.a. designed in ollaboration with Vapo Hydraulics n.v. in Belgium a digitally controlled hydraulic pallet lifting system with an accuracy of 0,1mm. This system ensures a perfect positioning in height without the use of supports on every single level of each storage rack. It also means that when the lift goes up, it can go straight to the exact position without the need to go a bit too high and to come back down afterwards to sit on the supports. On the lift safety and accuracy go together with speed.

As already mentioned above, each storage rack has 10 positions, including the buffer position at the ground level. The height from one level to another is 550mm. By using a double chain on a pulley (as used on forklifts) all 10 positions can be reached with 3m long cylinders. The lift is moved with 4 of these cylinders.

Seen that all pallets coming from the vibrating station are filled to the top of the side forms, the difference in level between all 4 cylinders should not exceed 2mm. The cylinders have a built-in magnetostrictive linear position sensor. In such a sensor a sonic strain pulse is induced in a specially designed magnetostrictive waveguide by the momentary interaction of two magnetic fields. One field comes from a movable permanent magnet which passes along the outside of the sensor tube, the other field comes from a current pulse or interrogation pulse applied along the waveguide. The interaction of the two magnetic fields produces a strain pulse, which travels at sonic speed along the waveguide until the pulse is detected at the head of the sensor.

The position of the magnet is determined with high precision by measuring the elapsed time between the application of the interrogation pulse and the arrival of the resulting strain pulse. Consequently, accurate non-contact position is achieved with absolutely no wear to the sensing components. The accuracy of the sensors applied is 0,01mm which results in an actual accuracy on the lift of 0,1mm.

112 -113

Some more difficulties had to be overcome: irregular loads on the pallets give irregular loads on the cylinders so normal hydraulic flow dividers could not be used, the stroke length of 3m results in a difference in behaviour of the hydraulic oil when the pistons are in their lowest or in their highest position. The system parameters have to be constantly adjusted in order to achieve a linear movement of the hydraulic cylinders. Therefore the use of a normal PLC was not an option, more adequate control engineering techniques had to be used.

Because of its reliability, CompactRIO from National Instruments Corp. was chosen as platform to control the system. The measuring method was developed in LabVIEW (also from National Instruments Corp.). The digital sensor signals reporting the positions of the cylinders are converted by a Field Programmable Gate Array (FPGA) to figures which can be used in the LabVIEW Real-Time programme which is the controller software.

These figures feed the Full State Feedback (FSF) system which controls the working pressure, the position and the speed of all four cylinders. The controller continuously evaluates the situation and can constantly adjust the flow to each cylinder. The operator interface was programmed (with LabVIEW) on a WinCC based touch panel module. The operator will not have to worry about any complex algorithm, he only has to indicate a position in one of the two storage racks where the pallet has to go to and the hydraulic lift will do the rest.

Conclusion:reliability and profitabilityTo minimise any type of delay in production both the Construx b.v.b.a. engineering staff and the Vapo Hydraulics n.v. service engineers have direct online access to the PLC of the circulation plant as well as to the controller of the hydraulic pallet lifting system. This backup procedure ensures a high reliability, thus meeting the customers requirements.Proven here is that sometimes it is better to focus on the most essential bottlenecks of a carrousel plant rather than trying to automate every single detail of the process. Costly and unnecessary investments, only in order to make the production process look more sophisticated, are to be avoided under all circumstances. A producer, whether it is a precast company or a machinery manufacturer, should always be determined to get the job done in the easiest (foolproof), quickest (on time) and cheapest (cost of labour, investment) way. A satisfied customer is the best reference a company can get.

ARCHITECTURAL FAÇADE ELEMENTS FOR THE

NEW HOSPITAL OF KORTRIJK: BOTH FIRST AND

SECOND PHASES.

All the elements consist of a base beam, 4 vertical

parallelogram-shaped columns and a top beam.

Production sequence:

In this way, all the components are cast separately and the diagonal tolerance of ±2mm is achieved, and above all the separate precast elements form a monolithic unit.

Project Production lines for façade elements

PRODUCTION LINES

BELGIUM

114 - 115

CIRCULATION PLANT FOR PREFABRICATION OF

MODULAR HOUSING UNITS.

The walls and floors are cast upside down in a tunnel formwork, after stripping they are turned 180° and transported to a finishing line. The precast divider walls and the precast roof are installed on this line.

Both in the tunnel form and on the finishing line, the

elements are positioned in the sequence in which they will be

assembled on the job.

The various actions are as follows:

in the hall

6 elements of 3m length can be cast daily on the 19,6m long tunnel form.

The basic units have the following properties:

Project Carrousel for housing units

PRODUCTION LINES

THE NETHERLANDS

116 - 117

Tricon

THE TRICON PANEL FORMWORK IS A

MULTIPURPOSE, ROBUST AND FLEXIBLE

SHUTTERING SYSTEM FOR ON-SITE

CONCRETE JOBS.

This shuttering system belongs to the category of heavy duty

modular panel systems.

The panels are made up of a high-quality galvanised steel

frame and a top quality 18mm plywood with a 440g/m² phenol coating.

System specifications:

Modular panel formwork system120mm

large surface

Limited number of parts which reduces the preparation time and simplifies the assembly and storage

80kN/m²

Long life expectancy due to galvanised frame and top quality plywood

Types of panels:

Wall panels: 3 heights (3300mm, 2700mm and 1200mm) each with 7 widths (2400mm, 1200mm, 900mm, 720mm, 600mm, 300mm and 240mm)Universal panels: 1 universal panel of 720mm wide per height, equipped with an extra hole pattern per 30mm, to use in corners, wall connections, as end panels and when making columnsFixed inside and outside corner panels: to make 90° angles Articulating inside and outside corner panels: to make sharp and blunt angles Shrinkable angle panels: to be used in lift shafts and stair cores

SHUTTERING SYSTEMS

118 - 119

Tricon

Assembly and fitting of the formwork:

Connecting the panels is done with the Tricon clamps, 2 per joint when using panels of 2700mm, the panels are clamped and aligned at the same time

compensation waler with a length of 850mm has integrated hooks and is universally utilizable to mutually reinforce and align joints between panels

tie holes in the centre, the smaller panels have tie holes left and right, the tie bars can be fitted through these holes

plug

panel must be tied

Applications and solutions:

Infills of 50mm, 60mm and 100mm are standard aluminium profiles, the standard Tricon clamp is used for the alignment, the tie bars are inserted through the infillsBetween 100mm and 360mm wide, the fillings must be made in timber, the planks are connected to the panel with the Tricon clamps, a Tricon compensation waler takes care of the alignment, the tie bars go through these compensation walersStraight angles are made by using an inside corner panel on the inside and 2 wall panels or a wall panel and a universal panel on the outsideSharp and blunt corners are made by using articulating corner panels on both sidesSingle-sided walls are made by using A-frames

SHUTTERING SYSTEMS

120 - 121

Conalu aluminium wall formwork

CONALU FORMWORK IS A MULTI-PURPOSE,

QUICK AND FLEXIBLE TO USE SHUTTERING

SYSTEM FOR ON-SITE CONCRETE JOBS.

This shuttering system belongs to the category of lightweight

modular panel systems.

The panels are made up of a high-quality aluminium frame and a top quality 18mm plywood with a 440g/m² phenol coating.



without a

crane is possible60kN/

m²

10mm increments

Long life expectancy due to aluminium frame and top quality plywood

Types of panels:

Wall panels: standard panel with 4 tie holesextensive range of panel dimensions

Wall panels with extra holes at 250mm away from the side profiles: when fitted sideways, these panels can be tied above the waterproofingColumn panels: provided with an extra hole pattern every 50mm, adjustable with 10mm increments by using an adjuster nut, to use in corners, wall connections, as end panels and when making columnsAdjacent panels: identical structure as the column panels but without the hole pattern, to be used in corners and as an infillBig size panels: widths of 2000mm, 2500mm and 3000mm, always fitted with extra holes for easy use in both waysFixed inside and outside corner panels: to make 90° angles Articulating inside and outside corner panels: to make sharp and blunt angles Corner columns: combination of inside corner panel and column panel, to be used where columns are integrated in a wall

SHUTTERING SYSTEMS

122 - 123

Conalu aluminium wall formwork


Connecting the panels takes place with the Conalu clamps, 2 per joint when using panels of 2650mmCompensation walers with different lengths serve to reinforce and align joints between panelsVariable Conalu clamps to be used with infills of up to 150mm

Unused tie holes must be sealed on the plate side with a plastic plug


Infills of up to 150mm wide are made in timber, fitted with variable Conalu clamps and aligned with compensation walersInfills larger than 150mm are made with timber Conalu profiles, coupled with standard Conalu clamps and aligned with compensation walers, the tie bars go through these compensation walers90° angles are made by using an inside corner panel on the inside and an outside corner panel or a combination of a column panel and an adjacent panel on the outsideSharp and blunt corners are made by using articulating corner panels that can be aligned with articulating compensation walersConventional columns are made by positioning 2 panels opposite to each other and by making the 2 other sides in timberWith 4 column panels in a hit-and-miss setup, columns can

be made with 10mm increments, the maximum section made with the 1000mm wide panels is 850mm x 850mmSingle-sided walls are made by using A-frames

SHUTTERING SYSTEMS

124 - 125

Conflex circular wall formwork

ANY CIRCULAR WALL WITH A MINIMUM

RADIUS OF 3M CAN BE CAST BY USING THIS

ADJUSTABLE AND QUICK TO FIT CIRCULAR

SHUTTERING SYSTEM.


circular panel systems.

The panels are made up of a high-quality galvanised steel box

and omega profiles and a top quality 18mm plywood with a 440g/m² phenol coating.

Adjusting the radii is extremely simple, thus making the Conflex system a cost-effective formwork.

System specifications and panel sizes:

3 heights (3300mm, 2700mm and 1200mm), each with 2

widths for the inside panels (2400mm and 1260mm) as well as for the outside panels (2500mm and 1300mm)Panel heights are identical to the panel heights of the Tricon

panels so nicely aligned joints will appear on the concrete surface when using Conflex and Tricon systems together

connect the tie barsspindles on the panels

to the outside steel profiles


Connecting the panels is done with the Tricon clamps, 3 per joint when using panels of 2700mm

they go through the compensation walers

plug


Conflex lifter can serve as a foot and as a lifting eye, 1 part for 2 functions

Conflex omega coupling simplifies the erection of one panel on top of another

Conflex spanner serves as an additional connection in between 2 panels

Conflex 800 bracket has a quick fit system and serves to make working platforms

Conflex prop connector, Tricon push-pull props can be fit anywhere in the slotted holes of the vertical omega profilesStop ends are made by using Conflex tie hooks and Tricon

compensation walers

SHUTTERING SYSTEMS

126 - 127

Quadri column formwork

THIS IS A HIT-AND-MISS COLUMN BOX SETUP

WITH INTEGRATED ACCESSORIES.

The Construx Quadri adjustable column box is quick and easy in use and has 4 important benefits: Perfect finish: A fair-faced concrete surface is achieved by working without

ties through the concrete and by screwing the plywood from the back of the frame Handy: With the same set, column boxes can be prepared with sections from 150mm x 150mm up to 850mm x 850mm, with 50mm increments The heights are similar to those of the standard Tricon panels: 1200mm, 2700mm and 3300mm Different column boxes can be assembled on top of each otherFast: All accessories are integrated in the formwork and a set of 4 panels can be moved on site in one single crane move

Stacked on a truck, a complete set takes up very little place

Strong: The robust construction allows for a pressure resistance of 80kN/m², a deflection limited to the minimum and an exception-ally long life expectancy

SHUTTERING SYSTEMS

128 - 129

Mega

THE MEGA SYSTEM IS A FULL STEEL PANEL

FORMWORK WITH STAINLESS STEEL SHEETING.

It is a multipurpose and robust wall shuttering system for

on-site concrete jobs where a fair-faced finish is required or

where extremely high concrete pressures occur.


wall form systems.

The panels are made up of a high-quality painted steel frame and a top quality 5mm stainless steel sheeting.

The special stainless steel alloy is magnetic in order to retain the benefit of working with magnets.

The steel sheeting sits on top of the box profiles of the frame and the joint in between 2 panels produces only a very thin line on the concrete surface



strong and rigid large size panelsLong life expectancy due to top quality 5mm stainless steel sheeting

compatible with the Tricon shuttering system

Limited number of parts which reduces the preparation time and simplifies the assembly and storage

100kN/m²

Types of panels:

Identical to the Tricon system3 heights: 3300mm, 2700mm and 1200mm7 widths: 2400mm, 1200mm, 900mm, 720mm, 600mm, 300mm and 240mm

Assembly, fitting, applications and solutions are similar to the

Tricon system

SHUTTERING SYSTEMS

130 - 131

Columns boxes

FIXED ROUND, SQUARE OR RECTANGULAR FULL

STEEL COLUMN BOXES HAVE THE ADVANTAGE

OF SPEED AND DURABILITY.

Their simple and robust construction makes them extremely suitable on building sites where large numbers of columns of the same type have to be made.

A standard column box set consists of the following components:

2 halves made up of a bended or rolled laser cut steel plate, horizontal laser cut ribs and vertical box profiles

thickness of the steel sheeting depends on the use and can be 4mm, 5mm or 6mm

connect the 2 halves we use conical round threaded bolts

and nuts which fit in tapered connections

Alignment plates welded onto the vertical box profiles, to align both halves and to make sure the joint produces only a very thin line on the concrete surface

integratedmultipurpose lifting lugs serve to lift the boxes but also to

connect 2 halves when sitting on top of each othertriangular

chamfers

Trolleys to move the column shuttering are optional

Other shapes of columns are feasible: elliptical, conical, etc...

COLUMNS

132 - 133

Precast battery moulds for on-site use: Multibat

TO MANUFACTURE BEAMS AND COLUMNS

ON SITE, A MULTIBAT CAN BE USED AS IN A

PRECAST FACTORY.

Manually movable formwork system for precast reinforced

concrete beams.

These battery moulds are composed of mobile steel panels with a 18mm multiplex or a 5mm stainless steel sheeting. These movable panels are set and fit opposite to a fixed panel.

The special stainless steel alloy is magnetic in order to retain the benefit of working with magnets, which is common practice in a prefabrication environment.

Customers can choose for a set-up with a fixed centre panel or a set-up with a fixed end panel.


arious heights on the different sides of that centre panel

elements on both right-hand and left-hand side can easily be finished by hand


Customers can choose out of a wide variation lengths and heights.Frequently chosen dimensions are:

Lengths: 8m, 10m, 12m and 14m

Heights: 750mm, 1000mm and 1250mm

The movable panels are fitted onto 6m long, double steel

profiles. Each set of profiles is equipped with 5 feet. There are also other profile lengths available, for instance 4,5m or 8m. Two of these sets are equipped with flat steel guide rails for the panels to roll on.

The panels are equipped with a built-in mechanism to lock and




Construx offers a wide range of bases, stop-ends, and height adjustments.

BEAMS / COLUMNS

134 - 135

Project Multibats

FRANCE

CONSTRUX SUPPLIED 8 IDENTICAL BATTERY

MOULDS TO THE SAME CUSTOMER TO BE USED

ON SITES IN FRANCE.

All 8 batteries have the following characteristics:

Length of the panels 8m

Height of the panels 1050mm

Fixed centre panel with working platform

1 mobile intermediate panel

and 1 mobile end panel

5mm stainless steel sheeting in 1 piece

Built-in working platforms and holders for handrails in order to comply with the stringent French safety regulations

The special stainless steel alloy is magnetic in order to retain the benefit of working with magnets, which is common practice in a prefabrication environment.

BEAMS / COLUMNS

136 -137

Formwork for piers

CONSTRUX DESIGNS AND MANUFACTURES FOR-

MWORK FOR ALL POSSIBLE TYPES OF PIERS.

Despite the fact that these are always customized jobs, it is pos-sible to design the formwork in such a way that parts can still be used afterwards on other jobs.

The tension and deflection of the formwork structure is calculated according to the execution details and the design is modified if required.

PILES

138 -139

Project Bridge pier formwork

HEAVY DUTY SHUTTERING FOR A VIADUCT ON A

LIGHT RAIL LINE SOUTH OF DUBLIN.

In total 30 pillars with widths of 10m and 12m and heights of up to 12m.

The complete formwork set consists of 40 large full steel panels

of 4375mm x 2500mm supplemented with lower size panels of 3125mm, 1250mm and 625mm.

Special features such as tapered stop-ends are included.

PILES

IRELAND

140 - 141

Project pier formwork

A SERIES OF SUPPORT PIERS FOR AN EXTENSION

OF THE MAIN AMSTERDAM RAILWAY STATION.

Columns with a height of 9,2m and a ground section of 3,3m x

1,15m.

It was decided to pump self-compacting concrete from below because of the specific situation:

A perfect fair-faced finish had to be achieved

The actual concrete pressures were more than 200kN/m².

PILES

THE NETHERLANDS

142 - 143

Swimming pool shuttering panel system

CUSTOMISED FULL STEEL PANELS WITH 5MM

STEEL SHEETING WHICH GUARANTEES A PER-

FECTLY SMOOTH CONCRETE SURFACE THAT

DOESN’T REQUIRE ANY FINISHING BEFORE

TILES OR LINER ARE FIT.

The panels are 1500mm or 1600mm high.A set consists of panels, adapter pieces and various accessories:

Standard big size panels, 2500mm wideStandard small size panels, 1000mm and 500mm wideCorner panels for inner and outer cornersInfills of 200mm, 100mm, 50mm, 20mm and 10mmCover casing formwork panels and their infillsAdjustable box-outs for gutters on top of the walls

stair moulds

Magnets and adapters for attaching skimmers, nozzles and lights

hooks, bolts and nuts, tie bars and wingnutstransport racks for the panels and bins for the

accessories

SWIMMING POOLS

144 - 145

Tunnel forms and wall forms

TO CAST WALLS AND SLABS DESIGNED WITH A

HIGH LEVEL OF REPETITION.

When the building is designed for the use of these shutters, it is definitely the most cost-effective way of casting concrete walls and slabs on site.

With these tunnel and wall forms you can achieve a fair-faced “ready to paint” concrete surface.

WALLS / FLOOR SLABS

146 - 147

SPECIAL FORMS

148 - 149

EDITORIAL

Combination of both precast

concrete and constructions

cast in situ

As soon as work began, after due consultations between the three companies involved in the project, TUC Rail, AM Valens - AB and Con-strux, the engineers decided to cast the pillars in situ and prefabricate the pillar heads in the concrete works. An additional process is then required to concrete the junctions between the two iris elements and the in situ produced con-crete pillars.

Adjustable formwork for the pillarsAll of the pillars have the same cross-shaped base and the same apex angle (located directly

below the iris head). Since all the pillars have different heights (the pillar height varies be-tween 4m and 14m, from the cross-shaped base to the rectangular head), the edges ris-ing from the cross-shape each have a differ-ent inclination angle. The only alternative to 34 individually designed formworks was a fully adjustable steel formwork. Due to the short-age of time, Construx built two complete sets of adjustable formwork. Since the formwork setting is different for each pillar, Construx de-cided to use scaffolding assemblies in conjunc-tion with the formwork components which can be individually adjusted to the cross-sectional area of the element. The adjustable formworks are set individually, in accordance with a route map, using a horizontal spindle mechanism.

The scaffolds not only act as assembly frames, but also relieve the pressure of the fresh con-crete, since the use of formwork anchors has not been authorized. Work platforms with ac-cess stairs and guard rails are installed on the outside of the scaffolding. The building is de-signed to comply with safety regulations cur-rently in force and also satisfies the contrac-

FORMWORK FOR THE IRIS VIADUCT

(PART OF THE DIABOLO PROJECT)

Diabolo is a major infrastructure project

that includes both a rail link between

Brussels Zaventem Airport and Antwerp

via the 25N railway line, and also a

connection on the same 25N line from

Schaerbeek out to the airport. AM Valens

- AB is constructing the 1.5 km long

route, an 810m long section of which

includes the so-called Iris Viaduct with

its 34 pillars. The TUC-Rail planners

based the design of the viaduct pillar

heads on the iris flower, the symbol of

the Brussels-Capital Region. Due to the

complexity of the design, AM Valens -

AB drafted Construx into the project to

develop the formwork systems required.

October 2010

150 - 151

tor’s requirements for high safety standards and easy access. Since the height of the bridge pillars varies greatly, Construx designed a modular formwork in three heights (2,250mm, 4,500mm and 6,750mm). These formwork modules can be installed on top of each other, either individually or in combination, as re-quired. Each individual module consists of two L-shaped segments.

Complex geometriesAs the geometry of each pillar is both complex and different in each case, the installation of the reinforcement caused significant problems. For this reason, Construx included in the plan a certain number of assembly scaffolds for reinforcement work, in order to ensure proper installation of the connection reinforcement.

Prefabrication of the iris heads in

the concrete production facility

Prefabrication of the iris heads in the concrete production facility is carried out in two mobile and hydraulically tiltable formworks. These formworks were pur-chased by A.M. Valens - AB, delivered to Dutch company Betonson and assembled by Construx. While the reinforcement is being laid in the first formwork inside the production hall and prepared for casting, the second formwork can be transported outside and placed vertically for concret-ing in. Three different heads must be made in the same basic formwork. In addition, all formwork surfaces are curved or twisted. The Construx engineers therefore had to consider sophisticated and complex forms when designing the formwork for precast

EDITORIAL

concrete production. The radii of the iris heads are formed with hydraulically ad-justable negative moulds, which later also facilitate stripping. After stripping, the pre-cast halves of the iris heads, each weigh-ing 80 tons, are shipped by barge from the manufacturing site in Son in the Nether-lands to Brussels. The precast is then un-loaded at night with a mobile crane onto a special transport vehicle and driven to the construction site. The support structure for transportation by ship and truck was also designed and built at Construx.

Hydraulically adjustable supportsIn order to install the precast iris heads, Construx developed four modular support structures including the formwork for the connection nodes. Each support structure features hydraulic height adjustment for the two halves of the iris heads, so that they can be accurately installed in their final posi-tion. The formwork for the connection node is then placed on the supporting structure, with which the 2m wide projection between the concrete pillar (cast in situ) and the two halves of the iris heads is concreted. Be-fore the supporting structure is dismantled, an erection scaffold must be installed on the top part of the iris head, and thereafter, the L-shaped side supports prefabricated by Betca are installed. The design of the scaf-fold and girder formwork was also carried out at Construx.

152 - 153

Integrated approachThe development and production of the vari-ous formwork systems for the Iris Viaduct are examples of the integrated approach that Construx can offer its customers. All form-work and manufacturing systems for in situ or precast concrete production are designed according to customer specifications for each individual project. Planning, design, calculation, fabrication and assembly are all carried out by Construx employees. This flexible and direct app roach makes for an effective analysis and correct implementation of the original concept. In this way, Construx acts more in the role of partner to its customers than supplier.

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Project Formwork for octagonal tanks

OCTAGONAL REACTOR PITS OF A CLEAR WATER

PRODUCTION FACILITY IN ANDIJK.

A series of 6 x 5 linked together octagonal tanks:

2 outer octagons of which 1 sits against an existing wall

Height of the walls 6430mm

1 complete set of formwork + 1 extra inside core

7 corner panels and 1 striking

panel

THE NETHERLANDS

CIVIL WORKS

154 - 155

Project Prison perimeter wall

THE PERIMETER WALL OF THIS PRISON IN

BEVEREN IS PERFECT FOR THE USE OF A

SELF-PROPELLED PORTAL FRAME SUSPENDED

FORMWORK:

Total length of the wall to be cast 970m’Height of the wall including top sphere 6,4m

Standard length of pouring phase 14,7m

7 equal parts of 2,1m wide

Accentuated joints of which the position varies per phase, carried out with magnetic trapezoidal chamfersNo tie bars through the wall, only underneath (below ground level) and over the wall

pumped from below with self-compacting concrete

via 2 openings with a concrete lock

the full length in order to let the air outMaximum deflection of 3mm over 6,4m height at a maximum concrete pressure of 160kN/m²

moved hydraulically

Opening and closing of the formwork is carried out hydraulically

Width of the foundation base is 2,5m, thus we constructed the portal frame to sit over a length of more than 15m, and doing so the formwork can be opened sufficiently for cleaning purposesAdjusting the height is done with jacks

converted to

lower heights to cast the inside walls of the prison

The 4 outer corners are poured first using special corner

pieces.Then the formwork is suspended in the portal frame to make the straight walls: 2 x 325m’ and 2 x 160m’.

The portal frame must therefore be reassembled 3 times, this only takes half a day.

BELGIUM

CIVIL WORKS

156 - 157

Project Prison perimeter wall

CIVIL WORKS

158 - 159158 - 159

Project Train station quays

THIS PROJECT IN GHENT CONSISTS OF 2 PARTS:

SCALES ALONG WITH THE MAIN PORTAL BEAM

The precast production consists of making 1 special and 2

standard elements per day.To accomplish this, the following formwork devices have been supplied:

2 hydraulic tilting tables 8m x 3,5m

2 curved superstructures to cast 1 element of 6010mm and 2 elements of 3390mm

On site a made to measure scaffold is used to support both the beams which are cast on site and the prefabricated scales which are to be mounted against these beams.

Details of the beams:Beam length between the columns 20,4m

Beam width 10,37m

Height to the underside of the beam 5,29m

2 complete scaffold sets of 20,4m’ are supplied.

Details of the scaffold and of the extra formwork, per set of 20,4m:9 standard frame structures length 3400mm2 adjustable frame structures length 900mm to 3300mm4 special heavy duty frame structures length 3400mm

These remain standing after stripping, carrying the full (half of 20,4m) load

a collapsible support for the

platform scales

Base forms with rubber sealantsFloor panels and adjustable side panels for the service quays

BELGIUM

CIVIL WORKS

160 - 161

Project Arch bridges

CONSTRUX SUPPLIED AN ARCH BRIDGE

FORMWORK FOR THE 3 INFRABEL BRIDGES IN

LANDEN, BERLOZ AND GINGELOM.

This formwork is self-supporting and sits only on the

abutments at either side of the railway tracks.

The formwork is modular and the point of view is to pour the largest of the 3 bridges in 2 phases.The formwork is to be moved to the second phase after striking

the first phase.

Details largest bridge:

Width on top, in the centre 10m

Width at the base 20,8m

Span 20,3m

Arch length 25,6m

Details of the formwork:

3 strips of formwork: 25,6m long x 2,5m wide, supplied in 6 equal parts of 12,8m x 2,5m6mm steel sheeting in 1 piece

the overlap between the 2 phasesReinforced transitions at the joint of the 2 arches2 triangular forms of 6m long x 3m wideFrame structure to join the strips, height 4m, width 2m, length 4mDouble bended side forms, total length 32m’, height 350mmSingle bended side forms, total length 25m’, height 350mmStriking devices at both abutments: 6 x 2,5m’ and 2 x 3m’

wheels and spindles

Rails and 2 winches to move the formworkhydraulic jacks to strike and lift

BELGIUM

CIVIL WORKS

162 - 163162 - 163

Assembly, striking and moving procedure:

Assemble arches per 2 sections (on frame structure) into strips of 25,6m long x 2,5m wide

Bolt the 3 strips together from above the formwork using continuous tie rods

crane Lift the complete set into position with the jacks

integrated manual spindles

Join horizontally on both side against the foundation beam

Horizontal releasing

Striking of the spindles and lowering of the complete setMove on to second phase using 2 winches

CIVIL WORKS

Project Arch bridges

164 - 165

Project Retaining walls

ON SITE POURING OF 6000M’ L-SHAPED

RETAINING WALLS IN SECTIONS OF 3M LONG

AND 2,2M HIGH, NEXT TO A RAILWAY TRACK IN

ANDERLECHT.

First the foundation slabs are poured with an opening of 200mm in between the slabs. Then the walls are poured on top of these slabs using shrinking dividers creating an expansion joint of 20mm in between the slabs.

The total order is 90m’ foundation slab formwork and 102m’

wall forms.

Foundation slab formwork:

15 double foundation slab boxes for 2 slabs of 3m long with a 200mm wide opening in between

articulating rear end to enable insertion of a geotextile mat

Wall forms:

7 formwork sets of 9m’

No tie bars through the wall, only under (at the 200mm wide opening in the slab) and over the wall

BELGIUM

CIVIL WORKS

166 - 167

Project Bridge piers and decking

FORMWORK FOR COLUMNS, BRIDGE PIERS AND

BRIDGE DECKS FOR A RAILWAY LINE EXTENSION

AT THE SOUTH OF BRUSSELS.

Column formwork:

diameter1780mm

6,9m

accentuated horizontal joints every 1,5m in height

key-hole shaped head

prefabricated concrete beam with round headsMould for concrete beam with 2 round heads

Bridge pier formwork:

Tapered round formwork

Height 8,8m

Diameter at the base 1,6m

Diameter at the top 2m

Bridge deck formwork:

2 bridge decks length 100m and width 7,5m

Prefabricated on site

and mounted in place3 phases

Formwork outside and inside for 1/3 bridge

Length of formwork 36m

Mould for the post-tensioning piles on top of the bridge decks

BELGIUM

CIVIL WORKS

168 - 169168 - 169

Project Bridge piers and decking

CIVIL WORKS

170 - 171

Project Self climbing circular formwork

FORMWORK FOR A CIRCULAR DRINK WATER

TANK WITH A PARTITION WALL INSIDE.

EQUIPPED WITH HYDRAULIC CYLINDERS TO

CLIMB AUTOMATICALLY.

The tank is made as an open caisson:

sunk by its own weight

carried out with a sharp angle

Continuous excavation inside the tank

drops systematically as the soil is removed and the wall is poured

Due to repetition and future similar works it was decided to use customised round formwork of which the inside can climb

hydraulically. This automatic climbing avoids the need to use a crane and thus keep the opening of the tank free for the removal of soil from inside.

Execution details:

Inner diameter 20m

Height 26,5m

Full circumference inside and outside formwork, poured in

1 go

height 2m

Partitioning wall between dry and wet part of the tank is poured afterwards

1m starter is cast on both ends of the partitioning wall in

phase 1

Outside formwork consists of 6 equal panels

Inside formwork on the dry side consists of 3 panels with 2

striking wedges and 3 hydraulic cylinders with a 2m stroke

for automatic climbing

Inside formwork on the wet side consists of 6 panels with 3

striking wedges and 6 hydraulic cylinders with a 2m stroke

for automatic climbing

panels (which allow the rebar of the partition wall to continue), at the same time stabilizing the formwork on both sides

UNITED KINGDOM

CIVIL WORKS

172 - 173

Magnets, side forms and bases

BOX MAGNETS:

housing, 10mm thick magnetic parts, fitted with a central bolt and two M16 threaded holes

ACCESSORIES FOR BOX MAGNETS:

be fitted to

TAPERED FLANGE MAGNETS:

horizontal and vertical surfaces

releasing

ACCESSORIES

174 - 175

Magnets, side forms and bases

STRAIGHT FLANGE MAGNETS:

other accessories

ROUND ANCHOR MAGNETS:

SIDE FORMS:

BASES:

ACCESSORIES

176 - 177

INDEX

Preface 4

Multibat 6Project: Multibat (France) 10

Bibat 12Project: Bibat (Belgium) 16

Tribat 18

Fixed table 20Project: Fixed table (Equatorial Guinea) 22

Tilting table 24Project: Tilting tables (Belgium) 28Project: Movable tilting table (Ireland) 30Project: Tilting tables (United Kingdom) 32

Spindle table 34

Hibat C 36

Hibat S 38Project: Hibat S (Belgium) 42Project: Hibat S (India) 44

Fully hydraulically adjustable horizontal stair mould 46Project: Fully hydraulically adjustable horizontal stair mould (Belgium) 50Project: Fully hydraulically adjustable horizontal stair mould

(Switzerland) 52Project: Hydraulically adjustable horizontal stair moulds with hand

pump (Poland) 53

Vertical stair mould with inserts 54Project: Vertical stair mould with inserts (France) 56

Combicaster 58Project: Combicaster (Belgium) 60

Lifting, tilting, transporting and storage of concrete and concrete elements 62Project: Concrete pump (France) 64Project: Tilting station (Belgium) 65

Formwork for tanks, box culverts, shafts and cores 66Project: Fixed and adjustable moulds for rainwater tanks, lubrication

pits and basements (Belgium) 70Project: Formwork for box culverts (Belgium) 72Project: Mould for wind turbine control pods (Germany) 74Project: Modular formwork for staircases and lift shafts (Belgium) 76Project: Moulds for substations (Belgium) 78

Formwork for Retaining Walls and Gutters 80Project: Formwork for Retaining walls (Belgium) 82

Formwork moulds and complete installations for prestressed elements 84Project: Prestressing beds (Belgium) 86 Project: Prestressed tank elements (United Kingdom) 88

Moulds for railway sleepers 90Project: Sleeper moulds, London Gateway (United Kingdom) 92

Retaining wall blocks 94

Special forms 96Project: Retaining walls (Belgium) 98Project: Viaduct elements (Belgium) 100Project: Prison cell walls (United Kingdom) 101Project: Tunnel elements (Norway) 102Project: Motorway barriers (Belgium) 103Project: Cornices (Turkmenistan) 104Project: Burial vaults (Belgium) 106

Project: Kasc (Saudi Arabia) 108

Redaction: Pumping Concrete in a new pallet circulation plant at C.F.Structures Ltd. in Summerhill, Ireland 110

Production lines 114

Project: Carrousel for housing units (The Netherlands) 116

Tricon steel wall formwork 118

Conalu aluminium wall formwork 122

Conflex circular wall formwork 126

Quadri column formwork 128

Mega stainless steel wall formwork 130

Column boxes 132

Precast battery moulds for on-site use: Multibat 134Project: Multibats (France) 136

Formwork for piers 138Project: Bridge pier formwork (Ireland) 140Project: Bridge pier formwork (The Netherlands) 142

Swimming pool shuttering panel system 144

Tunnel forms and wall forms 146

Special forms for on-site 148

Redaction: Formwork for the Iris Viaduct (part of the Diabolo project) 150

Civil works 154Total Project: Formwork for octagonal tanks (The Netherlands) 154Total Project: Prison perimeter wall (Belgium) 156Total Project: Train station quays (Belgium) 160Total Project: Arch bridges (Belgium) 162Total Project: Retaining walls Anderlecht (Belgium) 166Total Project: Bridge piers and decking (Belgium) 168Total Project: Self climbing circular formwork (United Kingdom) 172

Magnets, side forms and bases 174

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