concrete sleeper moulds

Equipment

sleeper mouldsMoulds and spacer bars

Moulds are manufactured in singles, twins and any other multiple.
Moulds are designed around the customers sleeper design.
Made from steel plate, jig assembled and jig welded to precise measurements.
The length and width is determined by the sleeper design and factory configuration.

The rail seats are designed to hold the fixation in the correct position.
Rail seats can be manufactured to suit any brand of fixation device.
Moulds are manufactured to very high tolerances as expected by the railways.

Spacer bars

These fit between the moulds and hold the strand/wire in the correct position during casting.

de-tension machine

Active passive steel work

The active end is used for multi stressing and de-tensioning.
The passive end can also be used for stressing but not de-tensioning.
These structures are manufactured from 75 mm steel plate.

Each bed requires one active and one passive end.

Approx size & weight: 2500 mm x 2000 mm x 500 mm. 3000 KG

Stressing and de-tensioning equipment

    • Single stressing Stressing one wire or strand at a time by hydraulic pump and cylinder.
    • Cavity stressing Stressing one cavity of wires or strands by hydraulic pump and cylinder.
    • Multi stressingStressing complete bed of wires or strands by hydraulic pump and cylinder.
      • To push the end plates clear between the moulds.
      • To run a full cavity of wires or strands from one end of the bed to the other.
      • To lock / unlock the pins holding the shoulders in the moulds.

Pumps and cylinders are calibrated for precise readings of applied loads

De-tensioning consists of 2 No. 250 Ton lock nut cylinders per bed. These cylinders are used for releasing the stressing forces into the sleepers after curing.

Casting machine

The casting machine run astride the moulds on the plant rails and places the concrete in the moulds and vibrates via high frequency internal vibrators.

Concrete is delivered to the casting machine by concrete skip and E.O.T crane.
Machine is fabricated from H beam & plate.
Hydraulic power unit controls drive in forward & reverse direction lifting of form plate & upper hoper door.
Vibration control is via Siemens frequency inverters.
Approx size & weight: 3500 mm x 2500 mm x 2800 mm. 4000 KG

Plate-wire-shoulder locking machine

This specially designed machine runs astride the moulds on the plant rail & its purpose is.

Machine is fabricated from H beam & plate. Hydraulic power unit controls drive in forward & reverse direction, plate pushing or pulling and lock unlocking of pins.
Approx size & weight: 2500 mm x 2500 mm x 1500 mm. 2500 KG

Saw machine

This machine run astride the moulds & cuts the pre-stressing strands or wires once the tension has been released.

Machine is fabricated from H beam & plate. Hydraulic power unit controls drive in forward and reverse direction, lifting and lowering of cutting head, locking onto moulds & traverse travel of cutting head.

Pumped water spray & dust covers.

Approx size & weight: 2500 mm x 2500 mm x 1800 mm. 3000 KG

De-moulding machine

This machine runs astride the moulds on the plant rail & lifts one mould at a time clear of the other moulds. Sleepers are then removed by hydraulic or mechanical grab. Machine is fabricated from H beam & plate. Hydraulic power unit controls drive in forward & reverse direction & mould lifting.

Approx size & weight: 2500 mm x 2500 mm x 1800 mm. 3000 KG

hydraulic craneMechanical or hydraulic grab

This machines hangs from over head crane. Mechanical grab is pushed out of mould lift machine by hydraulic cylinders removing the sleepers and turning them right way up by gravity. This machine works from the over head crane.

Hydraulic grab is lowered into mould lift machine & hydraulic cylinders extend to hold the sleepers while the mould is pulled down by the mould lift machine. Grab is then raised by over head crane, sleepers are rotated right way up.

Machines are fabricated from H beam & plate.