Butterfly Battery system

Formwork industry experts of B.T. innovation GmbH introduce a new system which brings the advantages of conventional prefabrication methods together. Foldable, double sided and removable forming platform, known as butterfly formwork® facilitates the production of concrete elements in a battery mould remarkably and makes new fields of application possible.

The system connects two worlds of precast production technology. Newly developed butterfly formwork® benefits from advantages of both horizontal preparation and vertical casting, in a smart way. Similar to circulation pallet production lines, all the preparation steps are carried out effectively in a horizontal status: from measuring with laser projections (or marking with plotters), to setting the necessary formwork shutters, placing the embedded parts, and exact positioning the reinforcement meshes or cages. Because of parallel preparation of elements on butterfly formworks independent of battery mould, the setting-up time is noticeably shortened.

By moving the prepared butterflies into the battery mould, horizontal position is changed to a vertical casting cell in which the concreting takes place. Typical advantages of upright production systems (as normal pocket battery moulds or box modular formworks) are retained in this system.

The idea of preparing butterflies in a recumbent position outside of battery mould can be upgraded to more efficient procedures used in carousel production systems. In this case, butterfly formworks are shifted by wheel drive engines to working stations where different tasks are accomplished consecutively.

 

In conventional battery moulds, mounting the fittings and placing reinforcement matrices take place one compartment after the other one, and only after the battery is emptied from precast elements of previous production round. On contrary in butterfly battery mould system, the preparation of several elements are carried out independently, simultaneously and out of battery mould. Therefore, the idle time of concrete curing in the battery’s casting cells is optimally used for preparing the butterflies of next round, which results in an enormous time saving.

As another positive factor, removing the elements together with the butterfly formworks makes it possible to start opening the battery mould when precast elements have reached a strength of almost 3 to 8 N/mm2. They will be stored outside of battery mould to get harder and then demolded from the butterflies. This procedure has enables our customers to reach up to 4 casting rounds in 24 hours which brings remarkably higher capacity.

Advantages of system solution

High performance
Battery Mould

BT Butterfly-
Battery Mould system

5 side formwork smooth precast elements (fair-faced)

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Compatible with magnet technology

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Lower investment requirement than table/pallet production systems

 

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Lower area requirement than table/pallet production systems

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Lower heating requirement than table/pallet production systems

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Prefabrication of solid walls

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Prefabrication of balcony slabs

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Prefabrication of floor/roof slabs

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1 layer façade elements

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2 layer insulated elements

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3 layer insulated sandwich walls

 

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Brick-faced precast elements (brick layer as façade + concrete element)

 

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Brick-faced insulated precast elements (brick layer + insulation layer + concrete layer)

 

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Compatibility with measurement and marking tools
(lasers and plotters, etc.)

 

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Horizontal formwork setting

 

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Horizontal reinforcement placing

 

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Horizontal positioning of pattern matrices

 

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Parallel working tasks outside of battery mould

 

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More than 3 concrete pouring per day

 

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Shorter emptying cycles of battery mould

 

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Alternative for tilting tables

 

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Advanced layout designs similar to carousel systems

 

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