Battery Mould

Battery moulds are used to produce large number of panel shaped concrete elements (flat components) with 5 fair-faced sides in a vertical way. The production of elements is carried out in several casting compartments which are mounted in a framework and separated from each other by bulkhead partition walls with formwork panels.

Therefore they are also referred to as pocket battery or toaster moulds. To absorb the hydrostatic force of concreting, the casting compartments are closed and tensioned between a fixed tension wall and a moving tension wall.

All kinds of battery forms basically consist of a number of similar, parallel positioned separating walls, which provide the space in between for the production. So called casting cells or cavities are surrounded underneath with the bottom shuttering and on both sides with side forms. Concrete pouring then takes place from top (open) side.

The configuration of battery system with one fixed end wall and one mobile tensioning wall is recognized as mono-battery or single battery mould. In duplex battery molds (double-battery), the fixed tension wall is positioned in middle of the production set, between hanging partition walls and the two mobile tension walls.

B.T. innovation GmbH develops tailored battery moulds for its clients, in addition to installation and commissioning. The number and size of production compartments are individually discussed and defined. Forming surfaces can be manufactured up to dimensions of 16m x 4.5m, jointless and in 1 piece. The steel plates are specially rolled and finely levelled for smooth formwork surfaces according to the agreed roughness measures.

 

Opening and closing (locking) the battery mold’s slots take place mechanically or electrically. Each casting pocket is additionally tensioned with a stiff and low-maintenance locking system. Due to especial design of BT battery forms, the access to all opened production slots are easily provided.

The side shutters of compartments are swiveling which facilitate the demolding process. Moreover, using the Magfly® magnetic technology of B.T. innovation as Magfly® AP and Multiform systems makes it much easier to place any side, middle and bottom shuttering, window cut outs and door opening formworks. Our Magfly® AP magnet offers the best adhesive force to weight ratio in its class worldwide, with only 5.40 kg mass and 22,000 N adhesive force.

Battery mould used to be a popular prefabrication machinery in late 60s and early 70s. However, after ever-growing application of high flow classes of concrete as F5 and F6, as well as self-compacting concretes (SCC), usage of battery moulds have significantly increased.

 

For Faster Construction!

To enable an accelerated prefabrication process, B.T. innovation has introduced a patented removable concrete precast formwork (butterfly form). The precast elements can be taken out from the battery mould together with the butterfly forms, after approx. 4 hours (strength of 3-8 N/mm2) and be stored out of battery mould to gain further strength. In this way, the battery is immediately available for the next concreting round. See also Butterfly Formwork®.

 

Advantages:

  • Precast elements with 5 sides form-smooth (fair-faced) surfaces.
  • Prefabrication of complicated wall elements in final installation position.
  • High flexibility for solid walls, slabs, façade elements, and balcony parts.
  • Jointless and monobloc formwork surface up to 16m x 4.5m
  • Optionally with removable formworks to accelerate the production.
  • Compatible with Butterfly Formwork® technology (optional)
  • Low area requirement
  • Possibility to future capacity increase
  • Available in single or duplex designs
  • Efficient and economic heating system due to compact design
  • Access paths and gangways to a safe working platform
  • Tailored machinery dimensions and setup design, customized to client’s requirements.