Construx - Shaping the Future of concrete - EN

EN

Shaping the Future of

oncrete

Your Partner in Precast & On-Site Formwork

EN

Shaping the Future of

oncrete

Your Partner in Precast & On-Site Formwork

CONSTRUX, YOUR PARTNER IN PRECAST AND ON-SITE FORMWORK

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.

The Construx team Ward Demyttenaere and Anthony Jannes Managing Directors

MISSION STATEMENT To 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 processes To 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.

VISION Construx 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: t 5SJDPO B TUFFM GSBNF XJUI QMZXPPE TIFFUJOH t .FHB B TUFFM GSBNF XJUI TUBJOMFTT TUFFM TIFFUJOH t $POBMV BO BMVNJOJVN GSBNF XJUI QMZXPPE TIFFUJOH 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.

STRATEGY Construx 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.

COMPANY HISTORY 2003 Founded as an engineering company.

2006 Joint-venture with “Constructie Demyttenaere” in Hulste to cope with the important missing link of inhouse 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 Roeselare 34.000m² total site surface area 9.000m² total production surface area 14 overhead cranes 31 welding units 26.000m² shuttering panels in rental 1.000.000kg steel processed annually 55 employees 11 CAD-workstations with different systems All design in 3D In-house production of all projects Directly 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)

4-5

BEAMS / COLUMNS

Multibat 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: t The option of selecting movable panels of various heights on the different sides of that centre panel t 'SPN UIF XPSLJOH QMBUGPSN PG UIF DFOUSF QBOFM UIF QSFDBTU elements on both right-hand and left-hand side can easily be finished by hand t 5IF CBUUFSZ NPVME JT BT JG JU XBT EJWJEFE JOUP TFDUJPOT BMMPXJOH 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: t Lengths: 8m, 10m, 12m and 14m t 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.

6 -7

BEAMS / COLUMNS

Multibat

8-9

BEAMS / COLUMNS

Project Multibat

FRANCE

THIS IS A SPECIAL MULTIBAT DESIGN FOR THE FRENCH MARKET. This manually movable formwork system is equipped with a ďŹ xed 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 beneďŹ t 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.

10 - 11

BEAMS / COLUMNS

Bibat HYDRAULICALLY MOVABLE BATTERY MOULD FOR PRECAST REINFORCED CONCRETE BEAMS AND COLUMNS. A standard configuration consists of 1 fixed centre panel and 2 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: t Fixed or modular panels, also available as removable and interchangeable partitions t Recesses to cast corbels together with the columns t Hydraulically adjustable supports to adjust both the lateral position and the height and width of the bases t Various manual systems for adjusting the base height t 'JYFE PS SFNPWBCMF triangular chamfers at the top the panels t Working 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.

12 - 13

BEAMS / COLUMNS

Bibat

14 - 15

BEAMS / COLUMNS

Project Bibat

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 ďŹ tting 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.

16 - 17

BEAMS / COLUMNS

Tribat 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.

18 - 19

FLOOR SLABS

Fixed table 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.

20 - 21

FLOOR SLABS

Project Fixed table

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 ďŹ tted onto the table by means of magnets.

22 - 23

WALLS

Tilting table TWO MAJOR ADVANTAGES OF THE USE OF TILTING TABLES: t 8"-- 1"/&-4 $"/ #& -*'5&% 0'' " 5"#-& WITHOUT DAMAGING THE SIDES IF THE TABLE IS TILTED INTO AN UPWARDS POSITION. t 8"-- 1"/&-4 /&&% 50 #& 4503&% */ 5)& 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.

24 - 25

WALLS

Tilting table 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.

26 - 27

WALLS

Project Tilting tables

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 FAIRFACED OR AN EXPOSED AGGREGATE FINISH. t 60 tables measuring 13m x 4m t 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: t 2 hydraulic cylinders (or 3 cylinders on the 16m long table) t 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 t The 13m long side form is divided in 2 equal parts of 6,5m t "MM TJEF GPSNT IBWF quick fixings at 140mm, 190mm and 250mm high t 5IF N TJEF GPSNT open hydraulically t 8 individual supports along the top 13m long side of the table so 4m high walls can easily be cast t High frequency vibrators connected to the centrally located frequency converter t Heating underneath the table t Insulation on the floor and on the sides of the table t 0QFSBUJPO CZ plug-in remote control to ensure safe working t "MM cabling for the hydraulics, electricity, heating and controls is concealed in covered gutters t 'VMM TUFFM TJEF GPSNT DBO CF mUUFE POUP UIF UBCMF CZ NFBOT PG 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.

28 - 29

WALLS

Project Movable tilting table

IRELAND

THIS TILTING TABLE MOVES FROM ONE END OF THE BUILDING TO THE OTHER END: t "-- 13&1"3"5*0/ "4 8&-- "4 1063*/( 5)& CONCRETE IS DONE IN A LOWER SECTION t 5)& 3&.07"- 0' 5)& 8"-- 1"/&-4 .645 #& 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: t high frequency vibrators t " frequency converter t Vibration absorbers between the upper structure and the tilting frame. t 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.

30 - 31

WALLS

Project Tilting tables

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.

32 - 33

WALLS / BEAMS

Spindle table 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 release them so they can be moved by hand.

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

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.

34 - 35

WALLS

Hibat C THE HIBAT “CARRIERâ€? 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 oor-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 ďŹ nish.

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 ďŹ t opposite to a ďŹ xed panel.

Customers can choose out of 2 set-ups: t A ďŹ xed centre panel combined with 2 movable end panels and a number of movable intermediate panels t " TFU VQ XJUI B ďŹ xed end panel combined with a movable end panel and a number of movable intermediate panels.

The centre panel set-up offers 2 major advantages: t From the working platform of the centre panel, the precast elements on both right-hand and left-hand side can easily be ďŹ nished by hand t 5IF CBUUFSZ NPVME JT BT JG JU XBT EJWJEFE JOUP TFDUJPOT BMMPXJOH to work independently in each individual section 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 ďŹ xed centre panel will have 1 to 3 intermediate panels on either side.

There are no ties going through the concrete.

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.

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

36 - 37

WALLS

Hibat S THE “SUSPENDED” HIBAT IS A HIGHPERFORMANCE 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.

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

38 - 39

WALLS

Hibat S

40 - 41

WALLS

Project Hibat S

BELGIUM

THIS PRECAST FACILITY HAS 2 VERTICAL WALL BATTERY MOULDS FOR PRODUCING FAIRFACED 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.

42 - 43

WALLS

Project Hibat S

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: t 1 fixed centre panel with integrated working platform t 2 x 5 movable intermediate panels t 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.

44 - 45

STAIRS

Fully hydraulically adjustable horizontal stair mould 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 ights 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

46 - 47

STAIRS

Fully hydraulically adjustable horizontal stair mould ďŹ rst 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 ďŹ xed 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: t Straight steps t Steps with cut-back t 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 ďŹ t 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.

48 - 49

STAIRS

Project Fully hydraulically adjustable horizontal stair mould

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.

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 ďŹ t 18mm plywood strips or 3mm metal plates onto which 15mm plywood strips are screwed.

All 3 moulds are equipped with a hydraulic tilting device.

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 ďŹ t 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.

52 - 53

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: t 4 adjustable bottom landing panels t BEKVTUBCMF UPQ MBOEJOH QBOFMT t MBOEJOH JOTFSUT t BEEJUJPOBM UBCMFT

54 - 55

STAIRS

Project Vertical stair mould with inserts

FRANCE

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: t Straight steps t Steps with cut-back t Steps with cut-back and nose Most of these inserts include a landing insert.

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: t 1 base panel 1800mm wide x 1500mm deep t QBOFMT NN XJEF Y NN EFFQ t QBOFMT NN XJEF Y NN EFFQ t NBHOFUJD DIBNGFST NN MPOH t NBHOFUJD DIBNGFST NN MPOH t TUFFM CPY NBHOFUT XJUI nBOHF LH GPSDF t QMBTUJD NBHOFUT LH GPSDF t "MM QSPQQJOH BOE BODIPSJOH BDDFTTPSJFT 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 - 59

STAIRS

Project Combicaster

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.

60 - 61

CONCRETE

Lifting, tilting, transporting and storage of concrete and concrete elements ACCESSORIES FOR HANDLING AND TRANSPORTING CONCRETE AND PRECAST CONCRETE ELEMENTS: t Spreader beams for transport and installation of precast and pre-stressed, concrete elements, such as beams and columns t Hoisting gear for transport and installation of precast concrete elements, such as tanks, lift shafts, staircases and box-culverts t Tilt hoists for installing precast concrete pillars on site. t Tilting equipment to turn over concrete elements t Racks for storage and transport of precast concrete wall panels t Concrete buckets for transporting concrete in a precast hall. t *OTUBMMBUJPO PG concrete pumps, placing booms t Storage for aggregates and concrete The equipment listed above is developed by Construx and CE certiďŹ ed.

62 - 63

CONCRETE

Project Concrete pump

FRANCE

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: t Supply shoot for ďŹ lling the pump by means of a concrete bucket t - buffer tank with electronic detection t Static concrete pump with 55kW electric motor t Hydraulic movement of the pump for cleaning purposes t Concrete transport from pump to boom over 50m t Hydraulically controlled placing boom, length 14m t Remote control for buffer tank, concrete pump and placing boom, all in one

Project Tilting station

BELGIUM

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.

64 - 65

TANKS / BOX CULVERTS / SHAFTS / CORES

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 ďŹ nd below a brief overview of the various types of precast elements for which this type of formwork is designed: t Lift shafts t Staircases t Transformer housings and electricity substations t Control buildings t Pipes t Collectors t Box culverts t Pits t Basements t Water tanks t Septic tanks Certain types of formwork have to be manually opened, closed and ďŹ xed, whereas others can be operated fully hydraulically.

In most cases, the precast elements are cast with selfcompacting concrete. Otherwise vibrators can be provided, either with or without a frequency converter.

66 - 67

TANKS / BOX CULVERTS / SHAFTS / CORES

Formwork for tanks, box culverts, shafts and cores

68 -69

TANKS / BOX CULVERTS / SHAFTS / CORES

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

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 ďŹ rst opened hydraulically, after which the hydraulic system pushes the oor upwards.

Overview of the types of tanks for which moulds have been purchased: t Oval tank 15000L t 0WBM UBOL t 3FDUBOHVMBS UBOL TNBMM NPEFM - NN Y # NN Y ) 1500mm t 3FDUBOHVMBS UBOL MBSHF NPEFM - NN Y # NN Y ) 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 oor.

All inner moulds shrink hydraulically and all outer moulds open manually.

The complete set consists of 1 ďŹ xed and 2 adjustable (modular) moulds: t Fixed mould: L 3240mm x B 2540mm x H 2100mm t "EKVTUBCMF NPVME - PS NN Y # NN Y ) 2100 or 3000mm t "EKVTUBCMF NPVME - PS NN Y # NN Y ) 2100 or 3000mm

70 - 71

TANKS / BOX CULVERTS / SHAFTS / CORES

Project Formwork for box culverts

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.

72 - 73

TANKS / BOX CULVERTS / SHAFTS / CORES

Project Mould for wind turbine control pods

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.

74 - 75

TANKS / BOX CULVERTS / SHAFTS / CORES

Project Modular formwork for staircases and lift shafts

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 ďŹ nishing 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.

76 - 77

TANKS / BOX CULVERTS / SHAFTS / CORES

Project Moulds for substations

BELGIUM

VARIOUS MOULDS FOR SUBSTATIONS FOR THE BELGIAN MARKET. Type 1: Single substation with fixed dimensions: t )FJHIU NN t 8JEUI NN t -FOHUI NN t 8BMM UIJDLOFTT BU UIF UPQ NN t 0GGTFU PG NN FYUFSOBMMZ NN GSPN UIF HSPVOE t 0GGTFU PG NN JOUFSOBMMZ NN GSPN UIF HSPVOE 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: t Height 2535mm t 8JEUI NN t -FOHUI NN t 8BMM UIJDLOFTT BU UIF UPQ NN t 8BMM UIJDLOFTT BU UIF CPUUPN NN Dimensions upper structure: t Height 1680mm t 8JEUI NN t -FOHUI NN t 8BMM UIJDLOFTT BU UIF UPQ NN t 8BMM UIJDLOFTT BU UIF CPUUPN NN 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 t Height 2500mm t 8JEUI NN t -FOHUI NN t 8BMM UIJDLOFTT NN t 5IF JOOFS GPSNXPSL IBT B wedge system in 2 corners to enable releasing.

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: t L-shaped retaining walls t T-shaped retaining walls t U-shaped retaining walls t U-shaped cable gutters, with or without feet t 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

RETAINING WALLS / GUTTERS

Project Formwork for Retaining walls

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: t U-sections, H 3m x L 2m x W 1,5m, capacity 2 x 2m’ or 1 x 4m’ t 6 TFDUJPOT ) N Y - N Y 8 N DBQBDJUZ Y N PS Y N t - TFDUJPOT ) N Y - N Y 8 N DBQBDJUZ Y N PS Y N The formwork for the L-sections is designed as a double mould, with 2 identical moulds positioned back to back.

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: t IV beams for industrial buildings t I-beams for bridges t Double T-beams for floors in buildings t Solid slab and hollow core floors for floors in buildings t Treble T-beams for roofs of industrial buildings t Railway sleepers and turn-out sleepers t Crane rail sleepers for portal cranes

84 - 85

PRESTRESSING

Project Prestressing beds

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 ďŹ xed 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.

86 - 87

PRESTRESSING

Project Prestressed tank elements

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: t 4 beds for standard elements t CFE GPS FMFNFOUT XJUI QPTU UFOTJPOJOH mUUJOHT 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.

88 - 89

PRESTRESSING

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

90 - 91

PRESTRESSING

Project Sleeper moulds, London Gateway

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.

92 - 93

BLOCKS

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.

94 - 95

SPECIAL FORMS

96 - 97

SPECIAL FORMS

Project Retaining walls

BELGIUM

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: t 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 t 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 t 1 hydraulic tilting device to place the vertical stands in an upright position on site t 1 tilting frame to ďŹ t the vertical supports on site

98 - 99

SPECIAL FORMS

Project Viaduct elements

BELGIUM

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: t Opening the side panels hydraulically t Reversing of the anchors manually t Pushing the elements up hydraulically (6 hydraulic cylinders)

Project Prison cell walls

UNITED KINGDOM

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: t Project 1: 3 complete moulds, fixed height, hydraulic opening and closing t 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.

100 - 101

SPECIAL FORMS

Project Tunnel elements

NORWAY

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 ďŹ nished with a curved vibrating screed and vibrators on the tables.

After curing, the elements are tilted and transported vertically.

Project Motorway barriers

BELGIUM

VARIOUS MOULDS FOR PRECAST CONCRETE MOTORWAY BARRIERS. Type 1: mould for 2 elements behind each other, with a length of 1m t $BTU VQTJEF EPXO UIFO UVSOFE PWFS t #PUI NBEF XJUI UPOHVF BOE HSPPWF t )FJHIU PG UIF DPODSFUF FMFNFOU JT NN t .PVME XJUI mYFE BO BSUJDVMBUJOH TJEF Type 2: mould for 2 elements next to each other, with a length of 6m t $BTU VQTJEF EPXO UIFO UVSOFE PWFS t #PUI NBEF XJUI UPOHVF BOE HSPPWF t )FJHIU PG UIF DPODSFUF FMFNFOU JT NN t 'JYFE NPVMET XJUI BSUJDVMBUJOH TUPQ FOET

102 - 103

SPECIAL FORMS

Project Cornices

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 45째.

104 - 105

SPECIAL FORMS

Project Burial vaults

BELGIUM

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 180째 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: t 10 internal moulds for double burial vaults t 20 external moulds for double burial vaults t 5 internal moulds for single burial vaults t 10 external moulds for single burial vaults t 1 electric tilting unit to turn the vaults 180째

Project Façade elements

BELGIUM

THESE FAÇADE ELEMENTS ARE SANDWICH PANELS AND ARE ALSO PRODUCED AS SUCH: t 5IF CSJDLT BSF QMBDFE JO UIF NPVME t #FUXFFO UIF CSJDLT BMM PQFOJOHT BSF mMMFE XJUI TBOE t $PODSFUF JT QPVSFE t 5IF GBÎBEF IBT B XIJUF DPODSFUF XJUI CSJDL JOMBZ GBDJOH t 5IF JOTVMBUJPO JT QMBDFE t 5IF TUSVDUVSBM HSFZ DPODSFUF JT DBTU PO UPQ PG UIF JOTVMBUJPO t "GUFS TUSJQQJOH UIF TBOE JT CMPXO BXBZ BOE UIF FMFNFOU JT flushed with white mortar The standard elements weigh 15,5T and measure 7,2m by 3,66m

106 - 107

SPECIAL FORMS

Project KASC

Saudi-Arabia

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.

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.

"DDPSEJOH UP UIFJS QPTJUJPO JO UIF GBÎBEF UIF 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: t 7 base frames t 3 fixed moulds in which only 1 specific type can be made t 4 adjustable moulds in which you are able to make 2 different types t 11 bases, one or more per type t 7 sets of 4 stop ends t Extra stop ends to be able to make V-elements

108 - 109

REDACTION December 2007

PUMPING CONCRETE IN A NEW PALLET CIRCULATION PLANT AT C.F.STRUCTURES LTD. IN SUMMERHILL, IRELAND In 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.

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.

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.

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.

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.

Extremely compact but very profitable circulation plant

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.

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

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.

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.

Pumping concrete in the plant by means of a stationary pump and a placing boom

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

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

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

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.

110 - 111

REDACTION

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.

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.

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.

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 profitability To 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.

112 -113

PRODUCTION LINES

Project Production lines for façade elements

BELGIUM

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: t *OWFSUFE DBTUJOH PG CBTF CFBN t $BTUJOH UPQ CFBN t 5VSOJOH BOE NPWJOH QSFDBTU CBTF CFBN UP DPMVNO DBTU QPTJUJPO t 1MBDJOH DPMVNO GPSNT POUP QSFDBTU CBTF CFBN t 1MBDJOH QSFDBTU UPQ CFBN PO DPMVNO GPSNT t $BTUJOH DPMVNOT UISPVHI PQFOJOHT JO UPQ CFBN 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.

114 - 115

PRODUCTION LINES

Project Carrousel for housing units

THE NETHERLANDS

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: t 1PVSJOH UIF DPODSFUF XBMMT BOE nPPST BT UVOOFM TFHNFOUT t )ZESBVMJD TUSJQQJOH PG UIF UVOOFM VOJUT t &MFDUSJD USBOTQPSUBUJPO PG FBDI JOEJWJEVBM VOJU t )ZESBVMJD MJGUJOH BOE mSTU ¡ UJMU t )ZESBVMJD DMBNQJOH BOE TFDPOE ¡ UJMU t )ZESBVMJD QVMMJOH POUP UIF EJBHPOBM USBOTQPSU MJOF t &MFDUSJD USBOTQPSUBUJPO UP mOJTIJOH MJOF t &MFDUSJD USBOTQPSUBUJPO PO mOJTIJOH MJOF t 1PTJUJPOJOH BOE mUUJOH QSFDBTU EJWJEFS XBMMT BOE UIF QSFDBTU SPPG t 3FMPDBUJOH UIF VOJUT WJB PWFSIFBE DSBOF UP UIFJS mOJTIJOH QPTJUJPO in the hall t 'JOJTIFE VOJUT UP CF XSBQQFE BOE TUPSFE JO UIF ZBSE 6 elements of 3m length can be cast daily on the 19,6m long tunnel form.

The basic units have the following properties: t 8JEUI NN t -FOHUI NN t )FJHIU NN t 8BMM UIJDLOFTT NN t 'MPPS UIJDLOFTT NN t 8FJHIU LH

116 - 117

SHUTTERING SYSTEMS

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: t Modular panel formwork system t 1BOFM UIJDLOFTT 120mm t 1BOFMT XJUI B large surface t Limited number of parts which reduces the preparation time and simplifies the assembly and storage t )JHI QSFTTVSF SFTJTUBODF 80kN/m² t Long life expectancy due to galvanised frame and top quality plywood Types of panels: t Wall panels: 3 heights (3300mm, 2700mm and 1200mm) each with 7 widths (2400mm, 1200mm, 900mm, 720mm, 600mm, 300mm and 240mm) t 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 columns t Fixed inside and outside corner panels: to make 90° angles t Articulating inside and outside corner panels: to make sharp and blunt angles t Shrinkable angle panels: to be used in lift shafts and stair cores

118 - 119

SHUTTERING SYSTEMS

Tricon Assembly and fitting of the formwork: t 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 t 5IF compensation waler with a length of 850mm has integrated hooks and is universally utilizable to mutually reinforce and align joints between panels t 5IF N XJEF QBOFMT IBWF tie holes in the centre, the smaller panels have tie holes left and right, the tie bars can be fitted through these holes t 6OVTFE UJF IPMFT NVTU CF TFBMFE PO UIF QMBUF TJEF XJUI B QMBTUJD plug t *G UIFSF BSF UXP EJGGFSFOU QBOFM XJEUIT TJEF CZ TJEF UIF XJEFTU panel must be tied Applications and solutions: t 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 infills t Between 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 walers t Straight 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 outside t Sharp and blunt corners are made by using articulating corner panels on both sides t Single-sided walls are made by using A-frames

120 - 121

SHUTTERING SYSTEMS

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.

System specifications: t Modular panel formwork system t 1BOFM UIJDLOFTT 120mm t &YUSFNFMZ nFYJCMF JO VTF t %VF UP UIF MJNJUFE XFJHIU PG UIF QBOFMT BTTFNCMZ without a crane is possible t 4VJUBCMF GPS DPODSFUF KPCT XJUI DPODSFUF QSFTTVSFT VQ UP 60kN/ m² t $PSOFS TFUVQ XJUI 10mm increments t Long life expectancy due to aluminium frame and top quality plywood Types of panels: t Wall panels: standard panel with 4 tie holes t &YUSFNFMZ extensive range of panel dimensions t Wall panels with extra holes at 250mm away from the side profiles: when fitted sideways, these panels can be tied above the waterproofing t Column 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 columns t Adjacent panels: identical structure as the column panels but without the hole pattern, to be used in corners and as an infill t Big size panels: widths of 2000mm, 2500mm and 3000mm, always fitted with extra holes for easy use in both ways t Fixed inside and outside corner panels: to make 90° angles t Articulating inside and outside corner panels: to make sharp and blunt angles t Corner columns: combination of inside corner panel and column panel, to be used where columns are integrated in a wall

122 - 123

SHUTTERING SYSTEMS

Conalu aluminium wall formwork

Assembly and fitting of the formwork: t Connecting the panels takes place with the Conalu clamps, 2 per joint when using panels of 2650mm t Compensation walers with different lengths serve to reinforce and align joints between panels t Variable Conalu clamps to be used with infills of up to 150mm t &WFSZ QBOFM JT mUUFE MFGU BOE SJHIU XJUI UJF IPMFT Unused tie holes must be sealed on the plate side with a plastic plug Applications and solutions: t Infills of up to 150mm wide are made in timber, fitted with variable Conalu clamps and aligned with compensation walers t Infills 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 walers t 90° 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 outside t Sharp and blunt corners are made by using articulating corner panels that can be aligned with articulating compensation walers t Conventional columns are made by positioning 2 panels opposite to each other and by making the 2 other sides in timber t With 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 850mm t Single-sided walls are made by using A-frames

124 - 125

SHUTTERING SYSTEMS

Conex 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. This shuttering system belongs to the category of heavy duty circular panel systems.

The panels are made up of a high-quality galvanised steel box and omega proďŹ les and a top quality 18mm plywood with a 440g/m² phenol coating.

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

System speciďŹ cations and panel sizes: t 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) t Panel heights are identical to the panel heights of the Tricon panels so nicely aligned joints will appear on the concrete surface when using Conex and Tricon systems together t 1BOFMT IBWF JOUFHSBUFE DPNQFOTBUJPO XBMFST XIJDI TFSWF UP connect the tie bars t 5IF SBEJJ DBO CF BEKVTUFE CZ VTJOH UIF spindles on the panels t "DDFTTPSJFT TVDI BT QSPQT TUPQ FOET BOE DPSCFMT DBO CF mUUFE to the outside steel proďŹ les Assembly and ďŹ tting of the formwork: t Connecting the panels is done with the Tricon clamps, 3 per joint when using panels of 2700mm t 'PS B XBMM IFJHIU PG NN UJF CBST BSF OFFEFE JO IFJHIU they go through the compensation walers t 6OVTFE UJF IPMFT NVTU CF TFBMFE PO UIF QMBUF TJEF XJUI B QMBTUJD plug Applications and solutions: t 5IF Conex lifter can serve as a foot and as a lifting eye, 1 part for 2 functions t 5IF Conex omega coupling simpliďŹ es the erection of one panel on top of another t 5IF Conex spanner serves as an additional connection in between 2 panels t 5IF Conex 800 bracket has a quick ďŹ t system and serves to make working platforms t 6TJOH UIF Conex prop connector, Tricon push-pull props can be ďŹ t anywhere in the slotted holes of the vertical omega proďŹ les t Stop ends are made by using Conex tie hooks and Tricon compensation walers

126 - 127

SHUTTERING SYSTEMS

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: t 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 t 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 other t Fast: 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 t Strong: The robust construction allows for a pressure resistance of 80kN/m², a deflection limited to the minimum and an exceptionally long life expectancy

128 - 129

SHUTTERING SYSTEMS

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.

This shuttering system belongs to the category of heavy duty 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 System specifications: t Modular panel formwork system t 1BOFM UIJDLOFTT 120mm t &YUSFNFMZ strong and rigid large size panels t Long life expectancy due to top quality 5mm stainless steel sheeting t 'VMMZ compatible with the Tricon shuttering system t Limited number of parts which reduces the preparation time and simplifies the assembly and storage t 7FSZ IJHI QSFTTVSF SFTJTUBODF 100kN/m² Types of panels: t Identical to the Tricon system t 3 heights: 3300mm, 2700mm and 1200mm t 7 widths: 2400mm, 1200mm, 900mm, 720mm, 600mm, 300mm and 240mm Assembly, fitting, applications and solutions are similar to the Tricon system

130 - 131

COLUMNS

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: t 2 halves made up of a bended or rolled laser cut steel plate, horizontal laser cut ribs and vertical box proďŹ les t 5IF thickness of the steel sheeting depends on the use and can be 4mm, 5mm or 6mm t 5P connect the 2 halves we use conical round threaded bolts and nuts which ďŹ t in tapered connections t Alignment plates welded onto the vertical box proďŹ les, to align both halves and to make sure the joint produces only a very thin line on the concrete surface t $POOFDUJPOT GPS QVTI QVMM QSPQT BOE XPSLJOH QMBUGPSNT BSF integrated t 5IF multipurpose lifting lugs serve to lift the boxes but also to connect 2 halves when sitting on top of each other t 4RVBSF BOE SFDUBOHVMBS CPYFT DBO CF mU XJUI TIBSQ triangular chamfers t Trolleys to move the column shuttering are optional Other shapes of columns are feasible: elliptical, conical, etc...

132 - 133

BEAMS / COLUMNS

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.

The centre panel set-up offers 3 major advantages: t 5IF PQUJPO PG TFMFDUJOH NPWBCMF QBOFMT PG Warious heights on the different sides of that centre panel t 'SPN UIF XPSLJOH QMBUGPSN PG UIF DFOUSF QBOFM UIF QSFDBTU elements on both right-hand and left-hand side can easily be finished by hand t 5IF CBUUFSZ NPVME JT BT JG JU XBT EJWJEFE JOUP TFDUJPOT BMMPXJOH to work independently in each individual section Customers can choose out of a wide variation lengths and heights.

Frequently chosen dimensions are: t Lengths: 8m, 10m, 12m and 14m t 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.

134 - 135

BEAMS / COLUMNS

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: t Length of the panels 8m t Height of the panels 1050mm t Fixed centre panel with working platform t 0O CPUI TJEFT PG UIF DFOUSF QBOFM 1 mobile intermediate panel and 1 mobile end panel t 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 beneďŹ t of working with magnets, which is common practice in a prefabrication environment.

136 -137

PILES

Formwork for piers CONSTRUX DESIGNS AND MANUFACTURES FORMWORK FOR ALL POSSIBLE TYPES OF PIERS. Despite the fact that these are always customized jobs, it is possible 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.

138 -139

PILES

Project Bridge pier formwork

IRELAND

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.

140 - 141

PILES

Project pier formwork

THE NETHERLANDS

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: t A perfect fair-faced finish had to be achieved t )VHF RVBOUJUZ PG TUFFM SFCBS t #JH QPVSJOH IFJHIU t 4NBMM PQFOJOH PO UPQ The actual concrete pressures were more than 200kN/m².

142 - 143

SWIMMING POOLS

Swimming pool shuttering panel system CUSTOMISED FULL STEEL PANELS WITH 5MM STEEL SHEETING WHICH GUARANTEES A PERFECTLY 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: t Standard big size panels, 2500mm wide t Standard small size panels, 1000mm and 500mm wide t Corner panels for inner and outer corners t Infills of 200mm, 100mm, 50mm, 20mm and 10mm t Cover casing formwork panels and their infills t Adjustable box-outs for gutters on top of the walls t *OUFHSBUFE stair moulds t Magnets and adapters for attaching skimmers, nozzles and lights t 4UBOEBSE BDDFTTPSJFT TVDI BT QSPQT TDBGGPME CSBDLFUT MJGUJOH hooks, bolts and nuts, tie bars and wingnuts t $VTUPNJ[FE transport racks for the panels and bins for the accessories

144 - 145

WALLS / FLOOR SLABS

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.

146 - 147

SPECIAL FORMS

148 - 149

EDITORIAL October 2010

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.

The scaffolds not only act as assembly frames, but also relieve the pressure of the fresh concrete, since the use of formwork anchors has not been authorized. Work platforms with access stairs and guard rails are installed on the outside of the scaffolding. The building is designed to comply with safety regulations currently in force and also satisďŹ es the contrac-

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 Construx, 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 concrete pillars.

Adjustable formwork for the pillars All 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 between 4m and 14m, from the cross-shaped base to the rectangular head), the edges rising from the cross-shape each have a different inclination angle. The only alternative to 34 individually designed formworks was a fully adjustable steel formwork. Due to the shortage of time, Construx built two complete sets of adjustable formwork. Since the formwork setting is different for each pillar, Construx decided to use scaffolding assemblies in conjunction 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.

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 required. Each individual module consists of two L-shaped segments.

Complex geometries As the geometry of each pillar is both complex and different in each case, the installation of the reinforcement caused signiďŹ cant 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 purchased 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 concreting 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

150 - 151

EDITORIAL

concrete production. The radii of the iris heads are formed with hydraulically adjustable negative moulds, which later also facilitate stripping. After stripping, the precast halves of the iris heads, each weighing 80 tons, are shipped by barge from the manufacturing site in Son in the Netherlands to Brussels. The precast is then unloaded 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 supports In 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 ďŹ nal position. 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. Before 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 scaffold and girder formwork was also carried out at Construx.

Integrated approach The development and production of the various formwork systems for the Iris Viaduct are examples of the integrated approach that Construx can offer its customers. All formwork and manufacturing systems for in situ or precast concrete production are designed according to customer speciďŹ cations for each individual project. Planning, design, calculation, fabrication and assembly are all carried out by Construx employees. This exible 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.

152 - 153

CIVIL WORKS

Project Formwork for octagonal tanks buy

*

,1

*

Click

8BOE :

8BOE (

8BOE '

8BOE (

8BOE (

8BOE $

'

8BOE #

8BOE #

8BOE $

8BOE $

8BOE &

8BOE %

:,-=,*,1*

:,-=,*,1*

8BOE %

8BOE &

:,-=,*,1*

:,-=,*,1*

(

8BOE &

8BOE %

8BOE %

8BOE &

8BOE 9

:,-=,*,1*

8BOE %

8BOE &

8BOE %

8BOE &

8BOE #

8BOE #

8BOE $

D

D

8BOE $

8BOE $

8BOE %

:,-=,*,1*

8BOE $

L/ NÃ

)

8BOE %

:,-=,*,1*

8BOE &

8BOE $

)

8BOE #

8BOE #

8BOE %

8BOE &

8BOE %

8BOE &

:,-=,*,1*

8BOE &

8BOE %

8BOE %

8BOE &

n

8BOE &

+

8BOE %

8BOE %

8BOE &

8BOE $

8BOE #

8BOE #

n

8BOE $

8BOE $

D

D

"MHFNFFO

8BOE 7

.BBUWPFSJOH JO NN )PPHUFNBUFO JO N U P W 1FJM UFO[JK BOEFST WFSNFME

1FJM JT / " 1 .BBJWFME $B 1FJM .BY $BMBNJUFJU HSPOEXBUFSQFJM 1 / " 1 "BSEJOH WBO EF DPOTUSVDUJF [JF & CFTUFL

+

5 1 ( #FUPO

)& #

)& #

)& #

)& #

)& #

3&/700*

8BOE ;

8BOE "

8BOE ;

8BOE "

8BOE 7

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

)& #

#

$

51( #FUPOWMPFS % NN

" 1FJMNBBU CPWFOLBOU DPOTUSVDUJFWMPFS # %JLUF DPOTUSVDUJFWMPFS $ 5PFMBBUCBSF WFSBOEFSMJKLF WMPFSCFMBTUJOH "OLFSSBJM )BMGFO %ZOBHSJQ );" UIFSNJTDI WFS[JOLU

TQFDJGJDBUJF MFJEJOH [JF UFLFOJOH 7#, UFL OS

NN

NN

%FUBJM D 4DIBBM

NN

(FUFLFOE

# #PFS

4DIBBM

(FDPOUSPMFFSE

- 4DIPPU 6JUFSLBNQ

(PFEHFLFVSE

3 ,PPMT

%BUVN

"OEL 'PSNBBU

"

7003$0%&

:,-=,*,1*

8FSLWMPFS NN

NN

4$)""-

1PTUCVT "& %FWFOUFS 5FMFGPPO 5FMFGBY

7MPFS 3FBDUPSFO

8FSLWMPFS NN

4DIBBM

"

.BTTJFWF 1MBBUWMPFS % NN

7MPFS 3FBDUPSFO

%FUBJM D

0WFSJHF

4$)""-

0QMFHSVCCFS 4#3 Y

,BML[BOETUFFO E NN

7MPFS 3FBDUPSFO

51( #FUPOXBOE % NN

51( #FUPOWMPFS % NN

7MPFS 3FBDUPSFO

51( #FUPOXBOE % NN

%FUBJM 1@ 4DIBBM

:

,-= ,*

13*5 ;JF XJK[JHJOHT QJKM HFU

,1

HFXJK[JHE

E E

HFU

HFXJK[JHE

E E

IPPGELBOUPPS

*

%FUBJM 1@

4DIBBM

SJKLTXFH "4 7FMTFSCSPFL QPTUCVT "$ 7FMTFSCSPFL UFMFGPPO UFMFGBY

MPLBUJF QMBBUT

POEFSEFFM

HFU HFL HF[ 1MPU %BUVN

POEFSXFSQ TPPSU UFLFOJOH

%SJOLXBUFSQSPEVDUJFCFESJKG "OEJKL 14"

4JY $FSBNBD HFCPVX 8FSLUFLFOJOH DPOTUSVDUJFT 7PSN 1MBUUFHSPOE SFBDUPSFO BT ' U N +

E E # #PFS - 4DIPPU 6JUFSLBNQ E E E E 3 ,PPMT

QXO QSPKFDU OS TDIBBM

BGEFMJOH

WPMH CMBE OS

"

% =6TFST=QSJU =%PDVNFOUT="OEL @60@4*9 $&3@QSJU SWU

8BOE 8

:,-=,*,1* :,-=,*,1*

3FWJU 5&,

8BOE &

8BOE #

8BOE %

8BOE &

:,-=,*,1*

)& #

8BOE 9

:,-=,*,1*

8BOE $

8BOE $

D

8BOE "

8BOE 7

8BOE %

8BOE ;

8BOE #

L/ NÃ

.BTTJFWF 1MBBUWMPFS % NN

)& #

)& #

)& #

D

8BOE ;

8BOE "

8BOE %

8BOE &

D

)& #

)& #

)& #

8BOE %

8BOE &

8BOE 7

8BOE $

8BOE $

8BOE #

8BOE ;

8BOE #

8BOE $

8BOE $

8BOE "

D

8BOE %

:,-=,*,1*

8BOE 8

8BOE 8

8BOE &

8BOE &

8BOE %

8BOE %

8BOE &

:,-=,*,1* :,-=,*,1*

8BOE &

8BOE #

8BOE ;

8BOE "

n

8BOE %

8BOE #

8BOE $

8BOE %

:,-=,*,1*

,BML[BOETUFFO E NN

8BOE &

8BOE %

8BOE &

8BOE %

8BOE #

8BOE #

8BOE $

8BOE &

8BOE %

8BOE 8

(

8BOE &

8BOE %

8BOE $

8BOE #

8BOE %

8BOE &

:,-=,*,1*

8BOE 8

:,-=,*,1*

8BOE 9

8BOE 9

L/ NÃ

8BOE &

8BOE %

D

8BOE #

D

8BOE $

+

8BOE &

8BOE %

8BOE &

:,-=,*,1*

D

:,-=,*,1*

8BOE 7

8BOE &

D

8BOE #

8BOE #

L/ NÃ

8BOE &

8BOE %

8BOE $

8BOE &

8BOE %

:,-=,*,1*

8BOE &

8BOE % 8BOE 7

8BOE 8

8BOE 8

:,-=,*,1* .BTTJFWF 1MBBUWMPFS % NN

8BOE 8

:,-=,*,1* :,-=,*,1*

8BOE %

L/ NÃ

8BOE $

8BOE %

8BOE &

:,-=,*,1*

8BOE #

8BOE #

L/ NÃ

8BOE $

8BOE 9

8BOE 9

:,-=,*,1*

:,-=,*,1*

8BOE &

8BOE %

8BOE &

8BOE %

:,-=,*,1*

:,-=,*,1*

8BOE 8

8BOE 8

:,-=,*,1*

8BOE 8

8BOE 8

.BTTJFWF 1MBBUWMPFS % NN

t 2 outer octagons of which 1 sits against an existing wall t JOOFS PDUBHPOT t Height of the walls 6430mm t 8BMM UIJDLOFTT NN t &YUFSOBM GBDFT NN XJEF t *OUFSOBM GBDFT NN XJEF t 1 complete set of formwork + 1 extra inside core t *OOFS GPSNXPSL DPOTJTUJOH PG 7 corner panels and 1 striking panel t 'PSNXPSL JODMVEFT TUPQ FOET BOE CPY PVU BU UIF UPQ MFWFM

m

8BOE 9

A series of 6 x 5 linked together octagonal tanks:

.c

'

,1

8BOE '

8BOE &

8BOE &

8BOE %

8BOE &

3FBDUPSTUSBBU HFNBBUWPFSE BMT UZQJDBM PWFSJHF TUSBUFO PWFSFFOLPNTUJH VJUWPFSFO

8BOE % 8BOE #

8BOE #

8BOE $

8BOE %

8BOE &

8BOE %

8BOE &

c u -tr a c k

E

8BOE &

,BML[BOETUFFO E NN

8BOE %

8BOE &

8BOE $

8BOE #

8BOE #

8BOE $

: ,-= ,*

8BOE 9

8BOE 9

:,-=,*,1*

do

8BOE :

8BOE %

:,-=,*,1*

:,-=,*,1*

:,-=,*,1*

8BOE %

8BOE &

:,-=,*,1*

8BOE &

8BOE %

8BOE &

8BOE %

n

8BOE #

8BOE #

8BOE 9

8BOE '

8BOE (

8BOE ' 8BOE $

8BOE &

8BOE %

:,-=,*,1*

8BOE %

8BOE &

:,-=,*,1*

:,-=,*,1*

G

8BOE :

*

: ,-= ,*

8BOE $

8BOE #

8BOE #

8BOE $

THE NETHERLANDS

8BOE 9

:,-=,*,1*

:,-=,*,1*

,1

: ,-= ,*

8BOE :

8BOE (

8BOE '

8BOE (

8BOE '

:,-=,*,1*

*

1@ 8BOE :

:,-=,*,1*

,1

G

* ,1 *

*

E

=,

,1

1@

,8BOE :

: ,-= ,*

:

E

G

: ,-= ,*

C

E

C

E

C

E

4DIBBM

1MBUUFHSPOE 3FBDUPSFO BT ' U N +

o

o

.c

8BOE 9

OCTAGONAL REACTOR PITS OF A CLEAR WATER PRODUCTION FACILITY IN ANDIJK.

w

to

buy

w.

w

w

c u -tr a c k

h a n g e Vi e

!

PD

XC

to Click

m

w

w

do

er

NOW

F-

w

NOW

h a n g e Vi e

!

XC

er

PD

F-

w.

154 - 155

CIVIL WORKS

Project Prison perimeter wall

BELGIUM

THE PERIMETER WALL OF THIS PRISON IN BEVEREN IS PERFECT FOR THE USE OF A SELF-PROPELLED PORTAL FRAME SUSPENDED FORMWORK: t Total length of the wall to be cast 970m’ t Height of the wall including top sphere 6,4m t 8BMM UIJDLOFTT NN t %JBNFUFS UPQ TQIFSF N t Standard length of pouring phase 14,7m t 'PSNXPSL NBEF PG 7 equal parts of 2,1m wide t Accentuated joints of which the position varies per phase, carried out with magnetic trapezoidal chamfers t No tie bars through the wall, only underneath (below ground level) and over the wall t 8BMM JT pumped from below with self-compacting concrete via 2 openings with a concrete lock t 0O UPQ UIF IBMWFT PG UIF TQIFSF SFNBJO PQFO GPS NN BDSPTT the full length in order to let the air out t Maximum deflection of 3mm over 6,4m height at a maximum concrete pressure of 160kN/m² t 'PSNXPSL JT TVTQFOEFE GSPN B QPSUBM GSBNF XIJDI DBO CF moved hydraulically t Opening and closing of the formwork is carried out hydraulically t 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 purposes t Adjusting the height is done with jacks t &YQBOTJPO KPJOUT JO TUBJOMFTT TUFFM NVTU CF QPTJUJPOFE QFSGFDUMZ t 5IF FOUJSF QPSUBM GSBNF BOE UIF GPSNXPSL DBO CF 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.

156 - 157

CIVIL WORKS

Project Prison perimeter wall

158 - 159

CIVIL WORKS

Project Train station quays

BELGIUM

THIS PROJECT IN GHENT CONSISTS OF 2 PARTS: t ."/6'"$563*/( 13&$"45 $0/$3&5& 4$"-&4 t 0/o4*5& 4$"''0-% 4:45&. 50 4611035 5)& 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: t 2 hydraulic tilting tables 8m x 3,5m t 2 curved superstructures to cast 1 element of 6010mm and 2 elements of 3390mm t 3FNPWBCMF CBTF BOE UPQ TJEF GPSNT t 3FNPWBCMF MBUFSBM JOUFSNFEJBUF TJEF GPSNT t 'PSNT GPS NBLJOH B UPQ VQT JO UIF TFDPOE QIBTF 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: t Beam length between the columns 20,4m t Beam width 10,37m t 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: t 9 standard frame structures length 3400mm t 2 adjustable frame structures length 900mm to 3300mm t 4 special heavy duty frame structures length 3400mm These remain standing after stripping, carrying the full (half of 20,4m) load t "MM GSBNF TUSVDUVSFT IBWF a collapsible support for the platform scales t Base forms with rubber sealants t Floor panels and adjustable side panels for the service quays t 4JEF GPSNT t 8PSLJOH QMBUGPSNT t USPMMFZT

160 - 161

CIVIL WORKS

Project Arch bridges

BELGIUM

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: t Width on top, in the centre 10m t Width at the base 20,8m t Span 20,3m t Arch length 25,6m Details of the formwork: t 3 strips of formwork: 25,6m long x 2,5m wide, supplied in 6 equal parts of 12,8m x 2,5m t 6mm steel sheeting in 1 piece t 5IFSF JT TVGmDJFOU XJEUI UP QPTJUJPO UIF TJEF GPSNT BOE UP NBLF the overlap between the 2 phases t Reinforced transitions at the joint of the 2 arches t 2 triangular forms of 6m long x 3m wide t Frame structure to join the strips, height 4m, width 2m, length 4m t Double bended side forms, total length 32m’, height 350mm t Single bended side forms, total length 25m’, height 350mm t Striking devices at both abutments: 6 x 2,5m’ and 2 x 3m’ t 4VQQPSUT XJUI wheels and spindles t Rails and 2 winches to move the formwork t .BOVBMMZ PQFSBUFE hydraulic jacks to strike and lift t )BOESBJMT BOE MJGUJOH CSBDLFUT

162 - 163

CIVIL WORKS

Project Arch bridges Assembly, striking and moving procedure: t Assemble arches per 2 sections (on frame structure) into strips of 25,6m long x 2,5m wide t -JGU UIF TUSJQT PWFS UIF SBJMXBZ USBDLT VTJOH UIF DSBOF t Bolt the 3 strips together from above the formwork using continuous tie rods t .PVOU UIF USJBOHVMBS GPSNT PG N MPOH Y N XJEF VTJOH UIF crane t Lift the complete set into position with the jacks t 4VQQPSU XJUI integrated manual spindles t Join horizontally on both side against the foundation beam t "TTFNCMF UIF TJEF GPSNT t 'JUUJOH UIF TUFFM QPVSJOH UIF DPODSFUF t $VSJOH PG UIF DPODSFUF t Horizontal releasing t Striking of the spindles and lowering of the complete set t Move on to second phase using 2 winches

164 - 165

CIVIL WORKS

Project Retaining walls

BELGIUM

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: t 15 double foundation slab boxes for 2 slabs of 3m long with a 200mm wide opening in between t "MM GPSNXPSL JT DBSSJFE PVU XJUI BO articulating rear end to enable insertion of a geotextile mat Wall forms: t 7 formwork sets of 9m’ t GPSNXPSL TFUT PG N t GPSNXPSL TFUT PG N t TUPQ FOET t TFUT PG TISJOLJOH EJWJEFST t No tie bars through the wall, only under (at the 200mm wide opening in the slab) and over the wall

166 - 167

CIVIL WORKS

Project Bridge piers and decking

BELGIUM

FORMWORK FOR COLUMNS, BRIDGE PIERS AND BRIDGE DECKS FOR A RAILWAY LINE EXTENSION AT THE SOUTH OF BRUSSELS. Column formwork: t 3PVOE DPMVNO CPY diameter1780mm t 7BSJPVT IFJHIUT XJUI B NBYJNVN PG 6,9m t &RVJQQFE XJUI accentuated horizontal joints every 1,5m in height t 8JUI BOE XJUIPVU key-hole shaped head t 8JUI BOE XJUIPVU TVQQPSU GPS MJHIUJOH QPMFT t %PVCMF SPX PG DPMVNOT XJUIPVU IFBE BSF MJOLFE XJUI BO PO TJUF prefabricated concrete beam with round heads t Mould for concrete beam with 2 round heads Bridge pier formwork: t Tapered round formwork t 'MBU QBSU MJOLFE UP TUBOEBSE TUFFM XBMM GPSNT t 5IF FOUJSFUZ JT BODIPSFE UP UIF FYJTUJOH QBSU PG UIF CSJEHF t Height 8,8m t Diameter at the base 1,6m t Diameter at the top 2m Bridge deck formwork: t 2 bridge decks length 100m and width 7,5m t Prefabricated on site t "GUFSXBSET UIFZ BSF NPWFE PWFS UIF DBOBM PO QPOUPPOT MJGUFE and mounted in place t #PUI CSJEHF EFDLT BSF QPVSFE JO 3 phases t Formwork outside and inside for 1/3 bridge t Length of formwork 36m t Mould for the post-tensioning piles on top of the bridge decks

168 - 169

CIVIL WORKS

Project Bridge piers and decking

170 - 171

CIVIL WORKS

Project Self climbing circular formwork

UNITED KINGDOM

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: t *U JT sunk by its own weight t 5IF MPXFS QIBTF JT carried out with a sharp angle t Continuous excavation inside the tank t 5IF UBOL 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: t Inner diameter 20m t 8BMM UIJDLOFTT NN t Height 26,5m t Full circumference inside and outside formwork, poured in 1 go t 'PSNXPSL height 2m t 1PVSJOH IFJHIU QFS QIBTF N t Partitioning wall between dry and wet part of the tank is poured afterwards t " 1m starter is cast on both ends of the partitioning wall in phase 1 t Outside formwork consists of 6 equal panels t 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 t 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 t 5IF DPOOFDUJPO CFUXFFO UIF ESZ BOE UIF XFU TJEF JT NBEF CZ panels (which allow the rebar of the partition wall to continue), at the same time stabilizing the formwork on both sides t 5IF MPXFS UJF CBS HPFT UISPVHI UIF XBMM t 5IF VQQFS UJF CBS HPFT PWFS UIF XBMM

172 - 173

ACCESSORIES

Magnets,┬аside forms and bases BOX MAGNETS: t )JHI QFSGPSNBODF NBHOFU JO TUBJOMFTT TUFFM CPY TIBQFE housing, 10mm thick magnetic parts, ямБtted with a central bolt and two M16 threaded holes t 1VMM PGG GPSDF GSPN LH UP LH t 6OJWFSTBM VTF UISPVHI BEBQUBCMF BDDFTTPSJFT t 5P CF VTFE XJUI TJEF GPSNT

ACCESSORIES FOR BOX MAGNETS: t 4USBJHIU CSBDLFUT JO WBSJPVT IFJHIUT t $PSOFS CSBDLFUT JO WBSJPVT IFJHIUT t $POOFDUPS CSBDLFUT GPS TUFFM TJEF GPSNT t 4JOHMF PS EPVCMF SPET UP IPPL UIF CPY NBHOFUT JOUP UIF CSBDLFUT t 5IF SPET BSF CPMUFE JO UIF . IPMFT JO UIF IPVTJOH t "OHMF TIBQFE BUUBDINFOUT UP XIJDI UIF UJNCFS TJEF GPSNT DBO be ямБtted to t 3FMFBTF CSBDLFU

TAPERED FLANGE MAGNETS: t 5BQFSFE nBOHF NBHOFUT GPS TFDVSJOH UISFBEFE BODIPST PO CPUI horizontal and vertical surfaces t 5IF NBHOFUJD DPSF JT QSPUFDUFE BHBJOTU DPSSPTJPO CZ B TUFFM QMBUF t 1VMM PGG GPSDF GSPN LH UP LH t " UBQFSFE GPSN BOE GSFFMZ SFWPMWJOH BEBQUFST TJNQMJmZ UIF releasing

174 - 175

ACCESSORIES

Magnets, side forms and bases STRAIGHT FLANGE MAGNETS: t 3PVOE NBHOFUT TQFDJBMMZ EFTJHOFE GPS UIF mUUJOH PG CPY PVUT BOE other accessories t 5IF NBHOFUJD DPSF JT QSPUFDUFE BHBJOTU DPSSPTJPO CZ B TUFFM QMBUF t 1VMM PGG GPSDF GSPN LH UP LH t UZQFT XJUI PS XJUIPVU UISFBEFE DPOOFDUJPO t 'SFFMZ SFWPMWJOH BEBQUFST TJNQMJmZ UIF SFMFBTJOH

ROUND ANCHOR MAGNETS: t 4FNJ TQIFSJDBM NBHOFUT t 1VMM PGG GPSDF GSPN LH UP LH t "QQMJDBCMF XIFO mUUJOH MJGUJOH BODIPST

SIDE FORMS: t 'VMM TUFFM t -PPTF mYFE BEKVTUBCMF PS BSUJDVMBUJOH TJEF GPSNT t #PMU PO PS UP CF mYFE XJUI JOUFHSBUFE PS TFQBSBUF CPY NBHOFUT t 0OF TJEFE PS UXP TJEFE GBDJOH t 4USBJHIU PS XJUI UPOHVF BOE HSPPWF t 8JUI PS XJUIPVU USJBOHVMBS DIBNGFST BU UIF CBTF BOE PO UIF UPQ

BASES: t 'VMM TUFFM t %JGGFSFOU UZQFT PG IFJHIU BEKVTUNFOUT t 8JEUIT NN NN NN NN FUD t 8JUI nBU PS USJBOHVMBS SVCCFS TFBMBOUT t &RVJQQFE XJUI MJGUJOH QPJOUT

176 - 177

INDEX

Preface

4

Multibat Project: Multibat (France)

6 10

Bibat Project: Bibat (Belgium)

12 16

Tribat

18

Fixed table Project: Fixed table (Equatorial Guinea)

20 22

Tilting table Project: Tilting tables (Belgium) Project: Movable tilting table (Ireland) Project: Tilting tables (United Kingdom)

24 28 30 32

Spindle table

34

Hibat C

36

Hibat S Project: Hibat S (Belgium) Project: Hibat S (India)

38 42 44

Fully hydraulically adjustable horizontal stair mould Project: Fully hydraulically adjustable horizontal stair mould (Belgium) Project: Fully hydraulically adjustable horizontal stair mould (Switzerland) Project: Hydraulically adjustable horizontal stair moulds with hand pump (Poland) Vertical stair mould with inserts Project: Vertical stair mould with inserts (France)

54 56

Combicaster Project: Combicaster (Belgium)

58 60

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

62 64 65

Retaining wall blocks Special forms Project: Retaining walls (Belgium) Project: Viaduct elements (Belgium) Project: Prison cell walls (United Kingdom) Project: Tunnel elements (Norway) Project: Motorway barriers (Belgium) Project: Cornices (Turkmenistan) Project: Burial vaults (Belgium) 1SPKFDU 'BĂŽBEF FMFNFOUT #FMHJVN

Project: Kasc (Saudi Arabia) 1SPKFDU 'BĂŽBEF FMFNFOUT #FMHJVN

94 96 98 100 101 102 103 104 106

108

Redaction: Pumping Concrete in a new pallet circulation plant at C.F.Structures Ltd. in Summerhill, Ireland 110 Production lines 1SPKFDU 1SPEVDUJPO MJOFT GPS GBĂŽBEF FMFNFOUT #FMHJVN

Project: Carrousel for housing units (The Netherlands)

114

116

Tricon steel wall formwork

118

46 50

Conalu aluminium wall formwork

122

Conex circular wall formwork

126

52

Quadri column formwork

128

Mega stainless steel wall formwork

130

Column boxes

132

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

134 136

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

138 140 142

Swimming pool shuttering panel system

144

Tunnel forms and wall forms

146

Special forms for on-site

148

53

Formwork for tanks, box culverts, shafts and cores Project: Fixed and adjustable moulds for rainwater tanks, lubrication pits and basements (Belgium) Project: Formwork for box culverts (Belgium) Project: Mould for wind turbine control pods (Germany) Project: Modular formwork for staircases and lift shafts (Belgium) Project: Moulds for substations (Belgium)

66

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

80 82

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

84 86 88

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

90 92

70 72 74 76 78

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

150

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

154 154 156 160 162 166 168 172

Magnets, side forms and bases

174

www.

Slingerweg 1 3600 Genk Belgium +32 89 32 88 55

.be Hazebeekstraat 11 8531Hulste Belgium +32 56 72 47 93

Kazandstraat 151 8800 Roeselare Belgium +32 51 25 11 95