Producing precast concrete parts efficiently with new plant technology - Butterfly Formwork®
The symbiosis of the patented Butterfly Formwork® with the proven Battery mould significantly accelerates the production process. The process opens up new application possibilities for the battery mould.
Two worlds are connected: the newly developed butterfly folding formwork from B.T. innovation makes smart use of the specific advantages of horizontal preparation and vertical production. As with circulating systems, all preparatory work can be carried out comfortably and effectively in the horizontal position: from measuring with laser (or marking with plotter), to formwork construction, positioning of the built-in parts and inserting the reinforcement.
Parallel work sequences on the horizontal shuttering tables outside the battery significantly reduce the set-up time, and the battery shuttering can then be completely loaded within a very short time.
Exploiting the advantages of battery moulds: B.T. innovation GmbH developed the patented Butterfly Formwork®, turning the battery mould into a Butterfly Battery®.
Groundbreaking: The shuttering areas are not only removable from the battery. They can also be moved between the individual workplaces with the help of roller conveyors/friction wheel drive, like the pallets of a circulation system.
The butterfly principle. The shuttering area is twice the size of the compartment in the battery. Once the preparation is complete, the butterfly is hooked into the battery casing with the crane. It folds up in the middle when lifted. The formwork surface thus moves from the horizontal preparation position to the vertical position for concreting. Not a single work step is required in the narrow battery formwork itself.
A conventional battery is not opened after concreting until the concrete has reached the necessary lifting strength. Butterfly, on the other hand, accelerates this process enormously. Here, the precast elements are lifted out together with the Butterfly Formwork® just a few hours after concreting and stored outside the battery to harden. Since the precast elements do not have to bear their own weight during lifting, the necessary waiting times are shortened. Already at a strength of 3-8N/mm², the precast elements can be removed from the battery together with the butterflies. Up to 4 concreting passes per day are possible, which can mean several 1000m² of precast.
* BT innovation distributes the Butterfly Formwork® and Butterfly Battery® for stationary applications on the basis of an exclusive licence from Umdasch Group NewCon.
| Advantages of system solution | High performance battery mould | BT Butterfly Formwork® |
|---|---|---|
| 5-sided formwork-smooth precast surfaces |
X | X |
| Magnetic technology suitable | X | X |
| Lower investment requirements than pure production with tilting tables or circulation systems | X | X |
| Less space required than pure production with tilting tables or circulation systems |
X | X |
| Lower heating requirement than pure production with tilting tables or circulation systems | X | X |
| Solid walls |
X | X |
| Balcony panels | X | X |
| Ceiling panels | X | X |
| Curtain walling 1-layer | X | X |
| Insulated elements 2-layer | X | X |
| Sandwich walls 3-layer, (core insulation) | X | |
| Precast clinker elements (prefabricated elements with clinker facing) | X | |
| Prefabricated clinker elements (clinker facing + core insulation) | X | |
| Calibration with laser projection | X | |
| Marking positioning with plotter | X | |
| Horizontal formwork construction | X | |
| Horizontal bonding of structural matrices | X | |
| Horizontal reinforcement construction | X | |
| Parallel work steps outside the battery | X | |
| More than 3 concreting operations per day | X | |
| Discharging the battery at < 8N/mm² Early strength | X | |
| Curing < 15N/mm² outside the battery | X | |
| Horizontal bonding of structural matrices | X | |
| Tilt-table function | X | |
| Can be integrated into circulation systems | X | |
| Available as a circulation system | X |