7.

A BATTERY MOULD
1 FRMAS EM BACTERIA
HSSEL )|H

Battery formworks for poles (with standard reinforcement) mainly consist of:
- a base framework manufactured from longitudinal and transverse commercial profiles of huge thickness, suitable to bear
the effects of vibration;
- the required number of cavities with a tray-shape (having a fixed dimension square section, with the minimum slope requi-
red for demoulding);
- the corresponding set of double-face casting separators (flat at one edge and tapered at the other one);
- vibrating installation and accelerated curing installation.
This battery production system offers great advantages in terms of production output, speed and quality of mass-produced
pre-cast poles.
These formworks can also be equipped with stressing/slackening heads to produce pre-stressed poles.

As frmas em bateria para a fabricao de estacas (com armadura passiva) so constitudos por:
- Uma estrutura de base construda com perfis comerciais longitudinais e transversais, de grande espessura, apropriados
para suportar os efeitos da vibrao;
- O nmero necessrio de bandejas em forma de tanque (seo quadrada de medida fixa, com pequena inclinao
necessria para a desforma);
- O conjunto de separadores "dupla face" (planos numa extremidade e afunilados no lado oposto);
- Instalao de vibrao e instalao de cura acelerada.
Este sistema de produo em bateria oferece notveis vantagens em termos de elevadas quantidades, velocidade e quali-
dade de produo de estacas.
As frmas em bateria para estacas podem ser equipadas cabeceiras de protenso/desprotenso para produzir estacas
protendidas.

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 7.A BATTERY MOULD
2 FRMAS EM BACTERIA
HSSEL )|H

Also battery formworks for the production of poles are used at best alongwith specifically designed operating machines which
can ensure the best results in terms of production and quality standards. In this specific case a self-propelling vibrating-
finishing machine is to be used. It slides along rails while performing its functions of pouring, compacting (vibrating) and
smoothing the concrete mix (recommended 5-6 cavities/trays at a time), with a thoroughly automatic cycle (pre-set
according to the vibration pitch).
The same machine will later also unwind and lay down the PVC insulation wrap along the whole formwork.
The vibrating-finishing machine is fed at best by a vertical downpouring bucket, equipped with a tilting handle on top for
hooking by the O.H.T. crane and an opening at its bottom with two synchronized gates, enabling the vibrating-finishing
machine to go on working uninterruptedly.

A produo de estacas em frmas tipo bateria pode ser melhorada com a complementao por mquinas dedicadas que
garantem mais elevados padres de produtividade e qualidade. Neste caso se trata de uma mquina acabadora/vibradora
autopropelida, sobre trilhos, com a funo de distribuio, compactao, e alisamento do concreto (5 tanques/frmas de
cada vez) com um ciclo completamente automatizado (predefinindo a frequncia vibrao).
A mesma mquina tambm coloca a lona de cobertura sobre toda a frma.
A acabadora/vibradora alimentada por uma caamba de descarga vertical, com ala de acoplamento ponte-rolante no
topo, e bocal inferior composto por duas aberturas sincronizados, permitindo mquina trabalhar ininterruptamente.

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 7.B CENTRIFUGE / SPINNING MACHINE
3 MQUINAS CENTRFUGAS
{EG|NF

Concrete spun poles are produced by means of spinning machines in which moulds are inserted to be spun. The process
is complete indeed with a set of other machines and specific accessories.
Basically such machines are meant for the production of pre-stressed or reinforced concrete cylindrical spun poles for
foundations or other applications. They ensure the maximum flexibility of production to manufacture concrete products
having regular shape, of any length and size, according to the required Standards.
Poles are designed and manufactured with particularly high concrete strength and tight tolerances; most often they are
cylindrical, hollow inside and uniform in thickness. However, different moulds can be inserted of any shape (circular,
square, hexagonal, octagonal, and decorative).
The possibility of working with the lowest water/cement ratio enables the manufacturer to increase the final resistance of
the concrete without jeopardizing its compactness and adherence to the internal steel reinforcement.

As estacas centrifugadas de concreto so produzidas com a utilizao de mquinas centrfugas onde so colocados os
moldes a serem centrifugados. O ciclo de produo completado com a utilizao de uma srie de outras mquinas e
acessrios especficos.
Essencialmente estas mquinas centrfugas so projetadas para a pr-fabricao de estacas cilndricas centrifugadas,
protendidas ou com armadura frouxa, para fundaes ou outros usos. Elas garantem a mxima flexibilidade de produo
para a fabricao de produtos de concreto com forma regular, de diversas larguras e comprimento, de acordo com as
normas exigidas.
As estacas so projetadas e fabricadas para garantir uma elevada resistncia do concreto e tolerncias dimensionais
mnimas. So geralmente de forma cilndrica, oca no centro, e com espessura constante, mas pode-se variar as frmas
para obter outros formatos (circular, quadrada, hexagonal, octogonal, e outras formas decorativas).
A possibilidade de trabalhar com uma relao gua/cimento muito reduzida permite aumentar a resistncia final do
artefato, sem comprometer a sua compacidade e a aderncia armadura de ao no interior.

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 7.B CENTRIFUGE / SPINNING MACHINE
4 MQUINAS CENTRFUGAS
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Preparation stages:

1. CONCRETE BATCHING
The concrete output quality of the batching plant is pivotal in the production of concrete spun poles. The concrete mix is
especially designed for such elements and constantly controlled, as it has to be extremely resistant, durable and waterproof
in any environment, even the most aggressive ones.

2. REBAR PROCESSING:
Pre-stressed concrete steel wires are automatically machine cut to the desired size and grips are placed for pre-stressing.
They are transferred to the filling area and attached to the head flanges of the mould. At the same time, tailor-made cages
are automatically machine welded with longitudinal and spiral wires (by cage-making machines).

Etapas de preparao:

1. CONCRETO
Na produo de estacas centrifugadas de concreto essencial a qualidade do concreto produzido na central de concreto.
A mistura de concreto especialmente concebida para tais elementos e constantemente controlada, pois tem de ser extre-
mamente resistente, durvel e impermevel em qualquer ambiente, mesmo os mais agressivos.

2. PREPARAO DA ARMADURA
Os fios de ao para a protenso so automaticamente cortados na medida com uma mquina especial e so fixados aos
terminais de pr-tensionamento. Eles so transportados ao longo das frmas e so fixados s flanges nas extremidades das
mesmas. Simultaneamente, as barras longitudinais e espirais, so soldadas mquina.

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 7.B CENTRIFUGE / SPINNING MACHINE
5 MQUINAS CENTRFUGAS
{EG|NF

3. MOULD PREPARATION AND CONCRETE CASTING:

Before casting, the moulds manufactured for the different sizes of poles are accurately cleaned (brushed) from debris of the
previous casting and sprayed with demoulding agent /oil.
The moulds for spun poles consist of two hinged halves. The lower half mould is positioned on special supports and a small
quantity of concrete is poured inside to provide a base for the cage to be placed. Longitudinal strands and conical spirals
are introduced into the mould and the head flanges are fixed. The concrete is distributed to fill the lower half mould by using
a mobile hopper sliding on rails or an injection pump or other casting devices. Once the filling operation is complete, longitu-
dinal edges for half moulds connection are cleaned and pneumatic screwers finally tighten the special closing bolts.The
pre-stressing strands/steel wires are placed and tensioned according to the pattern and specifications foreseen for the
specific project, by means of a hydraulic pump and properly sized cylinders. Strands are stressed one by one by means of
a tightener (a special hydraulic cylinder) ensuring the elongation evenness. The mould is then closed and suitably locked,
ready to be placed inside the spinning machine.

3. PREPARAO DAS FRMAS

Antes da concretagem, os moldes, construdos para diferentes tamanhos de estacas, so cuidadosamente limpos,
escovando-se os resduos de concreto anterior e pulverizao o desmoldante.
Os moldes para estacas centrifugadas so constitudos por duas metades articuladas. A metade inferior da frma coloca-
da sobre um suporte especial. posta em uma pequena quantidade de concreto como "base" para o posicionamento da
armadura. Os fios so dispostos ao longo do comprimento e espirais cnicas so introduzidas no molde antes de fixar as
flanges nas extremidades. O concreto distribudo na metade inferior da frma atravs de uma caamba mvel que desliza
sobre trilhos. Alternativamente pode ser usada tambm uma bomba de injeo e outros dispositivos de lanamento. Aps
o lanamento do concreto, as abas longitudinais que ligam as duas metades da frma so limpas e fechadas com parafusos
especiais e chave de fenda. Os fios / cabos de ao de pr-tensionamento so posicionados e esticados de acordo com as
especificaes estabelecidas para cada projeto, utilizando uma central hidrulica e um cilindro hidrulico adequadamente
dimensionado. Os fios so tensionados um a um atravs de um tensor (cilindro especial), que assegura um alongamento
uniforme. O molde ento fechado e trancado convenientemente, para ser posteriormente introduzido no centrifugador.

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 7.B CENTRIFUGE / SPINNING MACHINE
6 MQUINAS CENTRFUGAS
{EG|NF

4. PRODUCTION:
The spinning machine starts rotating after the mould has been located on its seat by the overhead travelling crane. Olmet
spinning machines are programmable with different spinning speed and time cycles (by an electronic control system for manual
and automatic operation). A sound-proofing structure can be applied to reduce the noise level of the spinning machine.
After spinning, the concrete reaches the maximum density and the residual water/cement ratio is very low. To ensure the
required concrete strength and to reduce the production time, accelerated curing is implemented. By means of bridge crane
(using a crane-beam), the mould is placed inside special curing chambers (equipped with thermo-electric probes) and steam is
injected in to speed up concrete curing.
5. DEMOULDING AND CLEANING
Once the curing stage is over, the bridge crane places the moulds in the removal area to be rotated and unlocked; eventually the
concrete poles are demoulded. The machine includes rolling cradles for mould rotation, vices group with jaws, guide equipment
for pole thrust, hydraulic cylinders for half-mould separation and vibrating units. Some types of poles require polishing by trowel
at their base. The finished products can be stacked for further natural curing. At this stage they are ready for Quality Control
tests, labelling and delivery.

3. PRODUO
A centrfuga comea a girar aps a frma ser corretamente posicionada sobre ela por meio de uma ponte rolante. As centrfugas
Olmet Italy so programveis para os ciclos de velocidade e rotao (equipadas com um sistema de controle eletrnico para a
gesto automtica e manual de todo o ciclo). Tambm pode ser aplicada uma estrutura para silenciar a mquina, para reduzir
os nveis de rudo. No final do ciclo de rotao, o concreto atinge o mximo de densidade e a proporo residual gua/cimento
muito baixa. A fim de assegurar a necessria resistncia do concreto e para reduzir os tempos de produo, utilizado o cura
acelerada. Com o uso de uma ponte rolante (usando um balancim), a frma colocada numa cmara de cura, injetado a
vapor para acelerar o processo de cura (temperaturas e tempos de ciclo de maturao so regulados por meio de sensores
termoeltricos).
4. DESFORMA E LIMPEZA
Depois de completamente curado, com uso da ponte rolante transfere-se a frma para a estao de desforma, em que os
moldes so abertos e girados. A centrfuga est equipada com beros rotativos para a rotao da frma, garras, guias para
empurrar, cilindros hidrulicos para a separao (abertura) das duas meias frmas, vibrador. Alguns tipos de estacas requerem
operao de alisamento na base por meio de esptula. Os produtos finais podem ser armazenados e guardados para uma cura
adicional temperatura ambiente. Neste ponto, eles esto prontos para a verificao do Controle de Qualidade, rotulagem e
entrega.

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