New global standards for 3D molds

As Europe's leading mold manufacturer, Construx has developed a full range of state-of-the-art 3D molds over the years. Either with fixed geometry, customizable or even fully automated, 3D molds are among the most complex molds due to their particular design, special features and technical specifications. Although Construx is "Top of Mind" when it comes to providing molds for electrical substations, prison cells and other types of pods, it continues to set new global standards for 3D molds. Recently, Construx has supplied various types of 3D molds to a number of precast manufacturers around the world.

Belgium: automated and hydraulically operated mold

Because the main walls of the substations are straight and only the basement walls, both inside and outside, are tapered, the demoulding must be done hydraulically. The mold has two hydraulically shrinkable inner cores and four hydraulically movable outer panels. Not only is shrinking and moving done hydraulically, but also securing the outer panels is done with a hydraulic wedge system. Before the outer panels can be fully opened, they are pushed back slightly by means of a hydraulically operated eccentric device. The actual demoulding of the element is started by pushing up the base and then lifting the element out of the mold by means of six perfectly synchronized hydraulic cylinders and six vents. Construx equipped the complete mold with electronic valves, sensors and a control panel, controlling all movements and ensuring the correct sequence of movements, resulting in a flawless system.

List of sensors:

- On each corner joint: check wedge open or wedge closed.

- On each wall: check whether the wall is open or not.

- On each corner of the shrink core: core all the way out or core all the way in.

- On the push-up system: check system off or system in / bottom in or bottom out.

Order of stripping operations:

- Pulling wedges at outside corners.

- Push walls open slightly.

- Fully open walls.

- Shrinking the inner core.

- Pushing up the concrete element.

Sequence of closing operations:

- Expanding the inner core.

- Close outer panels (pushers retracted).

- Secure the outer panels by closing the wedge joints.

An audible signal and a flashing light indicate when the jig is in operation.

The elements are poured upside down with self-compacting concrete. To facilitate the turning of the element, Construx supplied a special frame that connects the mold to the customer's turning device. All exterior panels are equipped with working platforms, one of which is equipped with stairs and the other three with access ladders. Construx also supplied a roof jig.

Substation dimensions:

- Length 3,525 mm x width 2,380 mm x height 2,780 mm.

- Wall thickness upper part: 80 mm.

- Interior and exterior basement walls with various tapers.

Netherlands: Hydraulically operated adjustable mold with complex geometry

This mold stands out for its special feature on the outer panels. The continuous recesses with an undulating pattern and the large bottom rebate, which surrounds the top of the mold, add to the difficulty of demoulding the elements. Construx designed the mold to accommodate two different element lengths. To allow for this adjustability, one of the outer panels can be placed in two different locations and one of the inner cores can be made larger or smaller by adding or removing a large insert. The mold has an inner core that is hydraulically pulled down, two hydraulically shrinkable inner cores and four hydraulically movable outer panels. Before the outer panels can be fully opened, they are pushed back slightly by a hydraulically operated eccentric device. The actual demoulding of the element is started by pushing up the base and then lifting the element out of the mold by means of several perfectly synchronized hydraulic cylinders and vents. All exterior panels are equipped with working platforms, two of which are equipped with an access ladder. The elements are poured upside down with self-compacting concrete. To facilitate element turning, Construx supplied a hydraulic turning device that is adjustable not only for the two actual substation types, but also for future elements with other dimensions. Construx also supplied adjustable basement and roof jigs.

Dimensions of substations:

- Length 2,449 mm and 3,449 mm x width 1,324 mm x height 2,190 mm.

- Interior and exterior walls with various tapers.

Shaping the Future of Concrete

Construx meets the requirements of each customer in order to obtain the most suitable solution for the manufacture of their prefabricated electrical substations. The result of achieving such an objective is always a highly satisfied customer. Construx is an engineering-driven manufacturing company that relies on the commitment, creativity and experience of its employees. Its goal is to establish a partnership, rather than being a supplier, in providing turnkey solutions to on-site precast and formwork problems.