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ELEMATIC BATTERY MOLDPROCESSESFOR WALL PRODUCTION
Battery molds vs. circulation line
BATTERY MOLD CIRCULATION LINE
Both sides are made against steel mold
� Smooth paint-ready surface
Top side has to be trowelled
� Quality variations may occur
Both surfaces get cured in similar
circumstances
� No bowing because of different
shrinkage
Bottom surface is denser than top
� Possible bowing because of different
shrinkage
Concrete is enveloped in the mold while
curing
� No moisture loss or condensation of
extra water
Top surface is open
� Possible moisture loss or condensation
of extra water
Panels are produced and handled vertical
� No need for tilting
� Saving of building space
Panels are horizontal during production
� Need for tilting before achieving the
design strength
� More factory building is needed
Applying retarder agent to the mold is
difficult
� Exposed aggregate finish is not possible
Retarder and cladding materials can be
used
�Various finishes can be used
Elematic battery molds
Elematic has two different battery mold systems available:
- Traditional battery mold system
- Cold shutter plate system
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TRADITIONAL BATTERY MOLDPROCESS
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Battery mold production process
Starting from completion of curing
1. Hydraulic clamping rams are released
2. End wall is moved enough to allow the cured panel(s) in the first cell to
be released and removed by an OH crane from the side of the mold.
3. Intermediate mold plates are moved one by one and cured elements
removed by an OH crane from the side of the mold.
4. Cleaning, oiling, reassembly of side forms etc. and placing of inserts and
reinforcement can start immediately after removal of elements from the
cells.
5. The battery is reassembled and tightened after preparation work in all
cells has been completed and inspected.
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Battery mold production process
6. Concrete is cast by a casting machine or casting skip, top surface is
smoothened and preferably covered to prevent dehydration.
7. Concrete temperature is increased and controlled during curing in
relation to speed of production, final strength and required stripping
strength.
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General concerns
• Surface quality
• Compaction
• Curing
• Labor
- Number
- Skill requirements
• Working environment
• Changeability, flexibility
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Surface quality
• Manufacturing in a battery mold gives plain and smooth surfaces on both
sides of the panel
• Concrete mix design affects the surface quality and Elematic has the know-
how and resources for finding the optimum recipe
• Magnetic fastening system for openings saves the mold surfaces from
damages
• Magnetic fastening system also makes furnishing work fast and efficient
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Compaction
• Wall panels with openings have been manufactured successfully in battery
molds for decades.
• Battery molds included in Elematic’s quotation have built-in vibrators to
ensure proper compaction even with ordinary concrete mixes.
• Introduction of SCC has made it easier, faster and even more economical.
• Sufficient tightness of the casting cells is achieved by seals on the edges of
the side forms.
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Enclosed curing
• Battery mold provides the most efficient and uniform accelerated curing
environment.
• As all the surfaces of the panel – with the exception of the top – are
surrounded with steel, no moisture is lost during the curing.
- no moisture loss = no loss of strength
- no humidity control system is needed
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Labor
• Skills requirements
- Unskilled worker can be easily trained to work on a battery mold
- No special hand-skills are needed
• Number of workers per shift (in battery mold lines)
- 11 workers per each 3-battery line
- In addition:
• one crane operator for each battery mold line
• 3 men for B&M plant
• 3 men for stock yard
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Working environment
• SAFETY
- Elematic battery molds are equipped with stairs, catwalks and railings for safe working on
the top of the mold.
- The top surface is flat with minimal obstructions.
- Movements of the leaves of the mold are slow and made manually No danger of men
getting squeezed.
• COMFORT
- Elematic battery mold is a compact package and emits very little heat
- Vibrators are enclosed inside the battery and the vibration energy goes into the concrete
- Floors are flat and free from pits, which helps cleaning (also and important safety issue!)
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Typical casting cell layout
Opening / First cell
Opening / Second cell
Cleaning and fitting
Cleaning and fitting (upper section)
Casting
Working on top of a battery mold
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Working on top of a battery mold
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End product
COLD SHUTTER PROCESS
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Cold shutter plate
22
Furnishing
• The cold shutter plates are
furnished outside the battery
mold.
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Furnishing
• Furnishing racks are situated in a
separate area close to the battery
molds
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Furnishing
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Furnishing
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Side forms are and opening molds are fastened by Elematic
magnets
Furnishing
• The furnished cold shutter plates
are then transferred into the
battery mold.
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Closing the furnished mold
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Cold shutter plates in a battery mold
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Battery mold ready for casting
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Casting
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Casting
• Battery molds are always cast up to
the surface.
• The bottom of the mold is
adjustable.
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Vibrating
• The vibrators are usually included
in the Elematic delivery.
• In case the vibrators aren’t
included, poker vibrators can be
used for vibrating (see picture).
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After casting
• The cast and pre-cured concrete
element is moved from the mold
for the rest of the curing.
• This accelerates the casting cycle
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After casting
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END PRODUCT
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Close-up of a battery-mold-made panelsurface
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Ornament on a battery-mold-made panel
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Ornament on a battery-mold-made panel
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Close-up of a battery-mold-made panelsurface with ornament
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Close-up of a battery-mold-made panelsurface and edge
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