Casting Module

Mould area: 8.0 meters long x 0.600 meters wide
Product height: 200 mm (max)
Product weight: 1400 kg.(max)

Feed hopper c/w structural frame work.

A 1.25 cu. m. hopper fitted with an under slung variable speed conveyor. This hopper travels longitudinally across the mould and is positioned in the parking bay during the de-mould cycle. Concrete is fed from this holding hopper to the mould via the variable speed conveyor. A scraper bar mounted to the front of the conveyor and is controlled with a hydraulic cylinder to level off the concrete in the mould.
Power requirements: 7 kW, 380/415 volt, 3 ph

Mould/core carrier

180 degree rotator (proportionally controlled)
Vibrators (10 – MVSI 3/800 S90)
Power requirements: 30 kW, 380/415 volt, 3ph

Pallet transfer conveyor

Mould, concrete and cores are rotated 180 deg. into the de-mould position; the cores are then retracted from the mould and the freshly manufactured concrete c/w the pallet is lowered uniformly from the mould onto a transfer conveyor. This transfer conveyor moves the pallet with the new product to the collection station.
Power requirements: 3 kW, 380/415 volt, 3 ph

Mould spray unit

A spray booth is mounted within a moving carriage. This carriage travels in the same structure as the feed hopper and is programmed to spray oil directly onto the mould in parallel with the insertion off the cores.
Power requirements: 3 kW, 380/415 volt, 3 ph

Core insertion/removal conveyor c/w bogie transfer unit

A 9 meter chain conveyor transfers the cores in and out of the mould. The bogey unit transfers the core removal / insertion conveyor from the casting station to the de-mould station.
Power requirements: 18 kW, 380/415 volt, 3 ph

Lowerator

Lowerator raises and lowers the pallet to enable the freshly cast product to be de-moulded on the pallet

Automatic/manual console

1. Proportional hopper travel speed/proportional conveyor speed plus variable scraper position during the selected feed hopper pass.
2. Proportional 180 degree mould position and vibration frequency/time selection during the 3 mould fill passes. Note a different frequency/time selection can be made on each pass.
3. Position of the pallet transfer conveyor. (fixed speed, soft start)
4. Mould spray bogey proportional travel speed plus start/stop mould position and spray booth upper/lower limits.
5. Proportional speed of the removal/insertion conveyor and the bogey fill/de-mould position

Pallet Handler No.1

Pallet Handler lowers an empty pallet onto the front position of the transfer car, unlocks the pallet, moves to the collect station to pick up a loaded pallet, delivers this pallet to the freshly cast product curing area, collects a loaded pallet from the cured area and delivers it to the rear position on the de-mould station, collects an empty and freshly brushed pallet from the front position, delivers this pallet to the empty station on the transfer conveyor of the casting station.

Pallet Handler automatic/manual console
Proportional travel/lift speed and hydraulic clamping
210 programmable stations plus 4 fixed stations
90 meter crane rail (2 x 45)
25 location stations, 4 location rollers/station

Pallet cleaner consisting of:

300mm dia. x 8 m long brush
Transfer conveyor

Pallet Handler No. 1 places a pallet with a cured product on the rear station of the pallet cleaner, unclamps the pallet, lifts up and moves forward to the front station, lowers down on top of an empty/brushed pallet, clamps pallet and lifts up and proceeds to the next station. After Pallet Handler No 2 has collected the cured product from the pallet, the transfer conveyor moves the pallet from the rear station, to the front station of the pallet cleaner.
Power requirements: 7 kW 380 /415 volt, 3 ph
Pallet cleaner automatic/manual control console

Pallet Handler No. 2

Lift capacity: 1500 kg, (product)
Travel speed: 0 – 40 meters / minute
Power requirements: 16 kW, 380/440 volt, 3 ph,
Proportional travel/lift speed plus hydraulic clamping
80 programmable stations + 2 fixed stations note 1 parking station
Pallet Handler No. 2 automatic / manual console

Mould 1

150 deep x 600 wide x 8000 mm long
160 Key inserts (2 row, 80/row)
5 x 75 mm dia. Core inserts c/w nose cones one end, pull brackets on the other end.

Mould 2

200 deep x 600 wide x 8000 mm long
160 Key inserts (2 row, 80/row)

Safety light curtains (3 sets)

Curing chamber guarding + gate with safety interlock
1 set Casting station
1 set Demould station
1 set Product removal (fork lift entry)

Pallets/Precast hollowcore flooring (200)

Product dimensions 600 mm x 8000 mm x 200 mm deep