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Steel moulds for concrete cast in place on site: piers, pier caps and track beds. We made 18 sets of pier and pier cap moulds, for piers 6 to 14 m high, for the elevated track of the Mumbai-Ahmedabad high-speed rail.
The mould is designed to your pier and cap drawings, trial-assembled in our works and sent with a supervisor for the first pours. The model shows a round pier 8 m high with its cap mould on top.
Scroll: the camera moves to each part in turn and ends on the exploded view. Drag to turn it round yourself.
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Cast in-situ moulds are set up on site, filled, struck and moved to the next pier. They have to go together the same way every time, so we trial-assemble each set before it leaves.
Scroll to see how it is built · drag to turn it round
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A steel shell round the pier, in lifts. Each lift is two half shells, so it opens to strip and closes again on the next pier.
Used here for: Pier shutter
In 2024 we were the only buyer of Deratech’s 20 kW, 12 m laser.
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Ring flanges join one lift to the next. Vertical flanges join the two half shells. Both are drilled to pattern so any lift fits any other.
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Vertical ribs and ring stiffeners keep the shell round under the pressure of wet concrete.
Used here for: Stiffeners
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Push-pull props to the ground plumb the shutter and hold it against wind.
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The pier cap carries the girders. Its mould has 2 long side shutters and 2 end shutters on ribs and walers. One set weighs about 25 T.
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The underside of the cap spreads out from the pier. Sloping soffit shutters form it, carried by struts and a collar on the pier shutter until the concrete has set.
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Platforms with handrails run round the pier and along the cap for the crew that pours. A caged ladder reaches them from the ground.
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The concrete pier, and the cap shown part filled. We also make track bed moulds, which set the line and level of the track on top of the viaduct.
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Pier shutter, flanges, stiffeners, cap shutters, soffit and platforms.
We fabricate to your drawings and prove the fit in our own bay before anything ships. Open any line for the detail.
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We fabricate to your design, from plate to a packed container. An engineer will tell you honestly how we would build it.
