Vibrated concrete products are produced in a continuous moulding cycle using a single mould equipped with high-frequency vibrators. Productivity is much higher than when using static moulds for classic concrete.
The strength of the concrete after vibro-compaction can reach Rck 50-60 Mpa, and the freshly de-moulded product can already be moved and positioned for curing. The advantage of using a single mould makes it possible to reduce the maintenance and cleaning operations of the moulds and allows to obtain elements that are all equal to each other, with great advantage and precision in the case of joining the elements. The production cycle of a mould lasts between 2 minutes and 10 minutes depending on the complexity of the element.
It is possible to insert metal reinforcement using plastic spacers. The metal cage must not interfere with the movement of the hydraulic cylinders. Hydraulic hooks are provided inside the mould for clamping the reinforcement.
Reinforcement fibres can be inserted upstream in the concrete mixer. Plastic fibres are preferable, as steel fibres may surface and rust, causing aesthetic problems. In general, fibres are not necessary as vibrated concrete achieves very good mechanical strength.
VibroCast self-propelled machines require minimal building infrastructure. A reinforced concrete floor with a well levelled and smooth surface is required for operation of the machine. The machine is self-propelled and can move freely over the surface. Power is supplied by means of a cable which can be dragged or suspended, and the switch cabinet must be located nearby. The concrete can be delivered by means of a bucket installed on the forklift truck, and the concrete mixing plant must be located close to the working area.
The hydraulic oil heater or cooler of the power pack can be optionally installed on the machine in order to be able to operate even in difficult climatic conditions. The operating range can be considered with ambient temperatures between +2C° and +50C°. The machine is designed to withstand wetting.
In the case of self-propelled machines, it is sufficient to have a concrete surface of at least 1,000 square metres, which is resistant to the pressure of the machine wheels, well levelled and smooth, and a concrete mixing plant located in the immediate vicinity of the machine. In addition, the delivery of concrete from the batching plant to the machine needs to be ensured, which can be done simply by means of a bucket with an ideal capacity of 1.5 m³ mounted on a forklift truck.
In the case of stationary plants, it is sufficient to have a suitable surface for curing the products.
The batching plant should preferably be equipped with a planetary mixer, which ensures better homogeneity of the semi-dry concrete.
The ideal concrete is semi-dry with slump S1-S2 (according to UNI EN 206 – 2006 and UNI 11104:2004).
The ideal water/cement ratio is approximately 40%.
Cycle times are between 2′ and 10′ depending on the size and geometric complexity of the element.
Each VibroCast mould maximises the number of elements that can be demoulded in each cycle, depending on their weight, volume and geometric shape.
VibroCast machines are equipped with a touch screen display and data communication apparatus with the Italian company, either by SIM card or by Wi-Fi line. All this allows the end user to detect and solve any problem that may occur during the machine’s life. Alternatively, it is always possible to send a technician from Italy or from the relevant area technical service.
The components of the vibroforming machine are of the world’s leading brands (Siemens, Danfoss, SKF, etc.) and are easy to find. The purchase of spare and wear parts is always possible directly from the manufacturer via an easy and intuitive online application.
The maximum power consumption of vibratory mixers and vibro presses is approximately 30kW.
In the case of concrete mixing plants, this depends on the size and complexity of the plant.
The machines are calibrated for European electrical standards of 400V and 50Hz. Modifications and certifications for different markets are possible according to customer request.
The moulds are interchangeable. The operation takes a maximum of 20 minutes. It is necessary to wash the mould thoroughly before storing it.
All machines can be dismantled for insertion in container boxes or flat racks. It is possible to evaluate the shipment of the monolithic plant inside wooden crates to be loaded out of shape on flat rack containers; this is possible in the case of vibroformers and vibro presses. If the monolithic plant is shipped, installation times on site are considerably reduced.
For production by means of vibrating, vibrating and piping machines, the machine operator, the operator at the concrete mixing plant and the operator of the forklift truck for transporting the concrete are sufficient.
VibroCast plants can be manual, semi-automatic or automatic. Generally, self-propelled machines are manual while stationary machines, integrated in more complex plants, are automatic.
In the case of automatic machines, the operator can set the appropriate parameters according to the product to be produced.
Self-propelled vibratory moulders generally demould products on the floor. In some cases it is possible to demould on steel decks that can be moved and positioned with a forklift truck. Stationary plants de-mould the products on steel decks that can be moved with trolleys or conveyor belts.
Concrete requires no special additives. The only ones are those used depending on the ambient temperature.
It is necessary to use a suitable demoulding agent for better release of the element from the mould.
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