The Mobile Battery Mould (MBM) for the production of precast concrete elements in immediate vicinity of the construction site

The concept of the Mobile Battery Mould has caused a sensation in the construction industry, after it became known, that two large construction companies in Singapore have opted for this concept independently of one another. In the meantime, both production plants have started operations successfully.

The response from selected customers was exceptionally positive, when Weckenmann Anlagentechnik GmbH & Co. KG presented its innovative concept of the transportable formwork. The reason for this is that using this technology the production of flat precast concrete elements can be directly relocated to where it is needed: to the immediate vicinity of the construction site. This represents a great advantage in view of the growing worldwide urbanization and the associated necessity to build large numbers of homes in a constantly high quality. Precast concrete elements are generally used for this. However, there are often no stationary precast plants nearby, making transport distances long and thus unprofitable, not to mention possible delivery delays or transport damages.

The Battery Mould in general is ideally suited for the production of solid walls. The concept allows that the heavy and large main components of the Battery Mould, the fixed central part and the movable exterior components as well as the hydraulic and electrical equipment can easily be transported while it does not exceed maximum transport dimensions and permissible axle load according to world-wide applicable standards. A special feature of the MBM is the controllable trailer, which improves the trailer's maneuverability significantly. This is especially important after the conclusion of the work, when the mould sometimes has to find its way out of very confined conditions on the site.

The mobile field factory from Weckenmann can be an ideal solution for large building sites: its investment costs are manageable, it produces just in time and it is enormously flexible. Thanks to its compact design it has a relatively small footprint and can be assembled or disassembled by a small number of people in just a few working days. The production process is accordingly easy to handle and includes a highly effective compaction facility in order to compensate for any fluctuations in the concrete quality. In addition, the optimal use of the hydration heat for the curing process and the possibility to preheat the formwork make the Mobile Battery Mould (MBM) very energy-efficient. The precast concrete elements are characterized by their high quality. Proof of that is the formwork-smooth surface on both sides.

The MBM offers the construction site all the advantages of the precast technology and avoids the disadvantages, which are caused in particular by additional transport. At the same time it meets the requirements of the construction site where restricted space conditions prevail, the number of qualified staff is limited and the environmental conditions always represent certain challenges.

There are many regions with local manufacturers of precast concrete elements that are able to supply large construction sites with suitable products but transport distances are often too long and thus non economical. Furthermore, long transport distances involve risks: the product can be damaged or there may be no suitable means of transport. Maybe, the infrastructure does not allow the transport of heavy precast concrete elements or the unpredictable traffic situation of the Megacities impede a predictable construction timetable as you never know, when the elements will be on-site. This problem can only be addressed by providing appropriate storage facilities of the elements on site.

Sustainability

A comparison of the Environmental Performance of a stationary precast plant in relation to the Mobile Battery Mould yielded in annual fuel savings of 36,000 liters of Diesel – assuming that 50m³ of concrete will be processed per day and the precast concrete plant is located 50km away from the construction site. This corresponds to CO2 savings of about 100 tons.

A further argument for the sustainability of the MBM represents the small energy requirements for the operation of the Battery Mould and the reusability of all components involved over many years.

MBM in operation in Singapore

At the end of last year two construction companies independent of each other from Singapore – Kimly Construction Pte. Ltd. and Tiong Seng Contractors (Pte) Ltd. - ordered the newly introduced product. The first two Mobile Battery Moulds have now been taken into operation simultaneously in the city state.

The Tiong Seng Group was already founded in 1959, and has since then developed to one of Singapore’s leading building contractors. In over 50 years of company history Tiong Seng has implemented a series of different projects, both in the public sector and in the private residential construction. In 2012 Tiong Seng put Singapore’s first automated circulation plant for the production of precast concrete elements into operation. The Mobile Battery Mould is now in operation for the construction of several buildings with around 22 storey buildings and a total of 1327 residential Units.

Kimly Construction Pte. Ltd has also many years of experience in the building industry and has successfully completed several building projects of the most diverse sizes in the city state. The company, established in 1975, has received several awards from official state authorities and possesses all necessary construction licences to build multi- storey buildings with in-situ concrete and precast concrete elements.

Both Mobile Battery Moulds are in operation on building sites for large housing projects within the urban area. Solid walls with thicknesses from 100- 300 mm are produced on the machines. The maximum dimensions of the precast elements are 3.5 x 7.1 m. A battery mould with 20 compartments thus has a gross formwork area of 497 m². The particular maneuverability of the MBM was successfully proven in the densely builtup urban area. Beyond that, noise levels remained below the permitted limits on noise Levels.

Both Mobile Battery Moulds are in operation on building sites for large housing projects within the urban area. Solid walls with thicknesses from 100- 300 mm are produced on the machines. The maximum dimensions of the precast elements are 3.5 x 7.1 m. A battery mould with 20 compartments thus has a gross formwork area of 497 m². The particular maneuverability of the MBM was successfully proven in the densely builtup urban area. Beyond that, noise levels remained below the permitted limits on noise Levels.

The Mobile Battery Mould (MBM) for the production of precast concrete elements in immediate vicinity of the construction site