Are you new to precast and wondering how to prepare high-quality precast panels and slabs with molds? Or maybe you just want to find a new, more efficient way of shuttering for sandwich panels, solid slabs, beams, columns, and other precast walls?
Either way, this Shuttering Guide provides you knowledge about the shuttering in general, difference between shuttering materials, best shuttering practices and gives a comprehensive overview of the Elematic FaMe Shuttering System.
Read straight through or go to the section you want to read!
- What to consider when choosing shuttering magnets?
- What is the difference between formwork and shuttering?
- Magnet shuttering enhances mold preparation process
- What is FaMe shuttering system?
- What are the main benefits of FaMe shuttering system?
- What is included in FaMe magnet shuttering system?
- Order a trial set
What to consider when choosing shuttering magnets?
- Size of the magnet matters especially when optimal utilization of casting surface is a priority.
- Weight of the shuttering magnets is an essential issue in manual handling. Even a difference of one or two kilos matters
- Weight-holding force ratio – the lighter magnet with more holding power is the best option. Holding force or retaining force is usually informed in kilos or N or kN. The range can vary from 450 kg up to 2100 kg, or from 4,5 kN to 21 kN
- Ease of handling is important for daily ergonomics. Check before purchasing how easy the magnets can be placed and released and what tools are offered for that.
- Pay attention to safety: Elematic push button magnets are designed to enhance safety and, in particular, to prevent finger injuries.
- Hot temperature resistance. Normal temperature thread for magnets is 60-70 C*. If you apply high temperature in curing chambers or have production in hot climate, you need magnets resistant to minimum 80 C*
You can start with just magnets
You can buy magnets only and use them with your current formwork materials. However, the most benefit you get from the shuttering system. The most effective modern shuttering solution is a modular system, which includes adjustable aluminum side profiles with plywood and magnets. The magnetic shuttering with aluminum profiles allows you to save time and money, reduce waste, remove need for welding and bolting, and increase production efficiency.
What is the difference between formwork and shuttering?
Formwork is an umbrella term that describes a process of making molds for reinforced concrete elements by using different materials. Formwork refers to both precast and cast-in-situ concrete pouring.
Shuttering is a type of formwork
Shuttering is a type of formwork. In precast concrete production, shuttering means manual, crane-assisted or fully automated assembly of molds for precast elements using different materials and parts. The shuttering often refers to the method of making the mold from water-resistant plywood. Advanced shuttering systems, such as Elematic FaMe, make this process easier and faster with magnets and aluminum profiles.
Different materials for precast concrete molds
Precast concrete is a construction product produced by casting concrete in a reusable mold or “form” or bed which is then cured in a controlled environment, transported to the construction site, and lifted into place. The precast concrete molds can be made of aluminum, timber, steel, plastic, fiber concrete, fiberglass or even rubber.
Magnet shuttering enhances mold preparation process
Lowering overall manufacturing costs and accelerating production are in the mind of every precast plant owner. The good news is that you can start to improve with small steps, which do not require massive investments. Here are few examples of how utilizing right shuttering materials and magnets can help to upgrade mold preparation.
For example, you have a precast wall production and want to maximize the usage of the casting table surface. Do you need to buy new tables? Not necessary. First try to change your formwork material and magnets. A compact multi-side magnet that fit into narrow places and have more than one jaw may be a solution. When you can use more than only one side of a magnet you can save space, time, and costs.
Sharp 90-degrees corners in door and window openings
Have challenges of keeping the corners straight in door and window openings? This is a common problem with wooden formwork widely applied in the wall production. The modern solution for that is aluminum side profiles, 90-degree corner pieces and magnets.
Get rid of crane handling
Heavy formwork materials like steel, and heavy magnets (if used) are time-consuming and unsafe combination that requires crane handling. Choose instead shuttering materials with weight of around four kilos per running meter for the average height of 150 mm and combine it with the lightest re-usable magnets. Then you can easily and safely move them without any lifting equipment.
Less material spend and cost savings
Want to save on mold costs over 10,000 euros annually? This tip is for manufacturers who still make mold of wooden materials. By replacing timber with aluminium profiles, you can almost half the timber spend and costs. Aluminum is re-usable, so you can cast directly on it. If you want to attach Al profiles to the plywood side forms, you need to purchase much less plywood than timber.
Less waste
Got tired of wooden waste in mold preparation? Our answer is – change to aluminum profiles and magnet shuttering. Even if you will use aluminum profiles in a combination with plywood, you do not need to change plywood side forms as often as the wooden forms. The result: you improve work safety, save money, and create less waste.
What is FaMe shuttering system?
FaMe shuttering is a patented modular system for preparing precast concrete molds for walls, beams and columns, including sides, door and window openings, and recesses for HEPAC installations.
Download a brochureHow FaMe works?
FaMe shuttering system works with any type of the formwork materials. It is usable on casting tables and beds with steel surface, and in vertical battery molds.
Prepare a precast casting mold of designed size and shape by using FaMe side profiles and shuttering magnets. The system provides quick operation leading to improved efficiency when setting out and breaking down the formwork.
What precast concrete products can I produce with FaMe?
What are the main benefits of FaMe shuttering system?
The benefits of FaMe are the same no matter how automated your production line is. FaMe magnet shuttering gives you a choice of preparing precast concrete molds faster and more efficiently even you have totally manual processes.
FaMe will save you up to 70% in shuttering time with even triple the efficiency of the precast production.
With FaMe you can:
- Produce elements with precise dimensioning
- Make straight 90-degree corners
- Use the same formwork for different element thicknesses
By using FaMe you will:
- Save money, time and space
- Increase profit
- Increase productivity
- Accelerate production speed
- Cut down on work phases
- Ensure safety
- Increase panel quality
- Reduce waste
Start with a limited number of components and simply add more as your need grows. You don’t need to invest in a whole new system. Start small, supplement the one you already have and get the latest improvements of FaMe along the way.
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What is included in FaMe magnet shuttering system?
FaMe systems includes the patented jaw-type magnets of various types, light aluminium side profiles with or without plywood, as well as other utensils.
Magnets hold the side forms during the casting and vibration processes.
MAGNETS PROFILES ACCESSORIES
Watch FaMe system in use
FaMe shuttering system
Order a trial set
Elematic offers an affordable trial set of magnets and side forms with a money-back guarantee. You can try to apply FaMe to your current formwork. For example, by using push-button magnets and aluminum adapter profiles. This is an easy jump to the new system.
The next step could be trying the aluminum side forms for shuttering of the entire mold or in the windows and doors.
We will be glad to guide you on the most efficient ways of using the system!