STRUCTURALPRECAST

A significant part of the PLAN SRL line is highly automated production equipment and
moulds for the manufacture of concrete structural precast elements for the manufacture of
industrial and commercial buildings:
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Foundations;
Columns;
Beams of various profiles both pre-stressed and reinforced;
Hollow-core slabs;
Roofing systems;
Wall panels;
Sound barrier.

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VIBRATED CONCRETE FOUNDATIONS AND COLUMNS

POCKET FOUNDATION
Foundations can be realized with totally or partially precast components. In the first case
foundations are used arranged directly on the path casting, in the second case the precast
side concerns only the pocket foundation with a slab.
Foundation
slab to be
casted

Pocket
foundation

Foundation pad connection reinforcement

PLAN suggests using the precast pocket foundation only to have greater stability of the
structure to be built and proposes the following solution:

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COLUMNS
Pictures of some column types that can be produced with PLAN Production centre for
columns.

The PLAN solution for the production of concrete columns provides a fast and flexible system for
the production of pre-cast columns with varying sizes, using a minimum of labour and ensuring that
the producer can modify the production centre and cast four different columns every single working
shift. The mould is designed to produce square or rectangular columns from 500x500 mm. to
800x1000 mm., including all the intermediate sections (in 100mm increments) by the use of
interchangeable modular bottom shutters that are positioned with a simple interlocking system and
are adjusted to height, in pre-set positions, by hydraulic actuators. This mould also allows the
producer to place corbels on any side and at any spacing that may be required. This is
accomplished by modular infill elements which have the shape of the desired corbel and replace
the modular shutter elements in the position required. The side shutters are opened and closed by
hydraulic cylinders and the bottom shutter moves sideways when the side shutters open, making
stripping a stress free operation, both for the pre-cast unit and the operator.

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SAMPLES OF COLUMNS

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No. 1 PRODUCTION CENTRE FOR COLUMNS

Single mould

Double mould
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Hydraulic power pack and control, for the movement of the bottom and lateral
shutter;

Width variable
side shutter
Height variable
bottom shutter

Heating system
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Vibration system

universal frame to fix end-shutters and/or types of corbels

Frame for corbel positioning

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WORKING PHASES

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PRESTRESSED CONCRETE BEAMS

PRODUCTION LINE FOR , and I beams with the following
specifications:
- Base frame with bottom;
- no. 2 sliding powered side shutters with additional opening for operator in charge for
reinforcement positioning;
- no. 2 reduction plugs sliding on the side shutter;
- connection superior tie-rods of closed side shutters;
- arrangement for steam heating system with tubes placed under the bottom;
- hydraulic system on board to open/close the side shutters and to regulate lateral plugs;
- arrangement for vibration system.

No. 28 double separators for the production of about 27 beams modular for every
width, made up of high tichk metal sheet, reinforced with lateral elements fast to be
disassemblied, hooks for overhead crane and coupling spacers.

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No. 1 set of stressing abutments 600 Ton capacity for foundations or self-stressing
made up of:
no. 1 anchorage for strand fixing;
no. 1 anchorage for multiple stressing machine positioning and sliding with
structure for strand fixing
No. 2 multiple stressing machines, 600 Ton capacity for multi strand stressing and
de-tensioning (release) of all strands to be fixed in front of the mould in order to reduce
the scraps. They are made up of:
double action hydraulic cylinders for multi-stressing and de-tensioning;
safety spacers hydraulically acrivated by copntrol at distance;
hydraulic system from hydraulic power pack;
safety devices;
arrangement for automatic locking system.
PLAN stressing system advantages
High stressing quality: by a very simple initial reinforcement alignment and
automatic speed change, which decreases when the load rises, this system permits
to avoid plastic deformation of wires. The load applied symmetrically permits to
avoid problems to the stressing abutments, to the self-stressing or to the
foundations.
Labour saving: with cycle time of 5 10 minutes for each mould as for length, the
multiple stressing permits a production cycle that is much shorter than the traditional
stressing systems.
Material saving: reinforcements are fixed to the ends of the moulds. In this way
scraps will be reduced at all.
Safety: stressing is done by means of controls at distance and the low speed makes
strand locking much safer and no operator need to operate directly in the
reinforcements and in the anchorages.

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HYDRAULIC POWER PACK

No. 1 hydraulic power pack to activate no. 1 stressing abutment at time both for multi
strand stressing and release and to activate cylinder safety spacers by executing
various operations in very safety conditions for operators.
Note: The hydraulic power pack could activate the stressing abutments of other moulds
too.

Optional
No. 2 AUTOMATIC STRAND LOCKING SYSTEMS. Not using manual clamps for
both anchorages makes strand locking/unlocking operations much easier and safer
and permits to cut strands at the end of the products instead of close to the
anchorages. In this way cut strands will be brought back to the anchorage to the other
side of the bed in order to avoid the gap between the total length of the bed and the
length of the casted bed.
MULTI-PURPOSE MACHINE for cleaning, strand pulling, oil distribution in mould and
measured beam cutting produced without using end shutters. The machine is made up
of:
no. 1 portal frame with powered wheels to run on rails combined to the mould for
beams;
no. 1 brushing unit with tangenzial brush to clean the bottom and no. 2 vertical
brushes to clean side shutters and plugs;
no. 1 oil distribution unit with nozzles to distribute oil equally into the bottom, in
the side shutters and plugs with aspiration system and filter;
no. 1 cutting unit with 1300 mm blade for transversal cutting and beam lenght
pragrammable measuring system;
no. 1 strand locking system for pulling on the mould.
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STRAND CUTTING AT THE END OF THE MOULD

MEASURED BEAM CUTTING WITHOUT USING END SHUTTERS

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STAIRCASE MANUFACTURING PLANT

No. 1 STANDARD DOUBLE MOULD FOR STAIRCASE PRODUCTION with the
following fixed dimensions and characteristics:
- production of 2 flight of stairs at time;
- minimum numbers of steps: 9
- max numbers of steps: 14
- flight width: from 900 mm to 1550 mm;
- steps with constant thickness: height 140 mm, length 331 mm;
- Base frame with beams with anti-vibrations to be fixed to the floor;
- no. 1 central fixed side shutter;
- no. 2 sliding lateral side shutters;
- hydraulically operated;
- pneumatic vibration system with 4 vibrators;

HYDRAULIC POWER PACK to activate side shutters and any bottoms.

Optional
- DOUBLE BOTTOM with adjustable height to cast always at the same level of the
upper side, hydraulically operated for the three moulds;

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No. 1 SINGLE ADJUSTABLE MOULD FOR STAIRS with the following characteristics:
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Casting thickness:
adjustable from 160 to 200 mm;
Stair width
adjustable from 250 to 300 mm;
Spessore dello sbarramento
adjustable from 100 to 260 mm;
Flight width
adjustable from 800 to 1700 mm;
Length of landing
adjustable from 0 to 1700 mm;
Flight length
adjustable from 2700 to 8000 mm;
Choice of plinth: (with or without) and position (up and/or down);
Number of steps
adjustable from 5 to18.
pneumatic vibration system with 4 vibrators;

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