U-Girder Mould

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How this mould works

A U-girder is a trough. It needs outer shutters for the outside and an inner core for the inside.

Scroll to see how it is built · drag to turn it round

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Side shutters

A steel skin plate follows the outline of the unit on each side. It is cut on the laser and formed to the section.

How is it possible at Allmarc?

Deratech Supera-H 12030 fibre laser20 kW

Used here for: Side shutters

In 2024 we were the only buyer of Deratech’s 20 kW, 12 m laser.

• 20 kW
• 12 x 3 m bed
• Pallet changer

All our machinery

Deratech 8 m tandem press brake8 m bending length

Used here for: Side shutters

• 8 m bending length
• Tandem technology

All our machinery

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Ribs and walers

A rib every metre and walers along the length hold the skin to shape against the pressure of wet concrete.

How is it possible at Allmarc?

ABB robotic MIG welding cellsThree-phase robotic MIG

Used here for: Ribs and walers

• Three-phase robotic MIG
• Automatic special-purpose welding machines

All our machinery

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Soffit bed and base frame

The unit is cast on the soffit bed. The bed sits on longitudinal and cross beams on legs, bolted down and levelled.

How is it possible at Allmarc?

Kotec newRun10DX CNC beam drilling lineH-beams up to 1,000 x 500 mm

Used here for: Soffit bed and base frame

Heavy profiles that need precise holes, where plasma cannot do the job: the lower structure and panel borders of a ground flare, and every bolted PEB and multi-storey frame.

• H-beams up to 1,000 x 500 mm
• Drills 3 faces in one pass
• Channels, angles and box sections

All our machinery

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Inner core

The inner core forms the inside of the unit. It lifts out or collapses inward to strip.

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Props and clamps

Screw props or clamps hold each shutter in place and pull it back to strip.

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End bulkheads

Stop ends cut to the section close the mould at each end.

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Walkways and vibrators

Grated walkways with handrails run along both sides for the pour. External vibrators on the walers compact the concrete through the skin.

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The unit it casts

The concrete unit is shown part way along the mould.

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Every part

Shutters, ribs, soffit, base frame and bulkheads.