Hydraulic functions matched to the mould sequence

A hydraulic formwork operating system assists the movement of large mould sections that would otherwise require difficult manual handling. Depending on the formwork concept, hydraulic cylinders may be used for opening, closing, lifting, lowering, aligning or releasing selected parts of the mould.

The system must be developed from the mechanism and operating sequence. Cylinder force alone is not enough: stroke, mounting angle, pin loads, synchronisation, structural reactions and mechanical locking all affect reliable operation.

System features

  • cylinders selected for the required force, stroke and installation geometry;
  • fabricated brackets and load-transfer points integrated with the mould frame;
  • hydraulic power unit sized for the operating groups and duty cycle;
  • valve groups and controls arranged around the approved sequence;
  • pressure monitoring and travel limits where required by the control concept;
  • protected hose routing that avoids access areas and moving interfaces;
  • mechanical stops and locks to secure production positions;
  • maintenance access for seals, pins, hoses and connection points.

Where several cylinders move one long form, the design must address how movement is coordinated and how uneven travel is detected or corrected. The final control scope depends on mould stiffness, required accuracy and the buyer's automation standard.

Application scenarios

Hydraulic operating systems are used on U-beam, box girder, segmental beam and other large precast moulds. They can be applied to new equipment or considered during the upgrade of an existing mould, provided the original structure and load paths are verified.

Useful project inputs include mould drawings, moving-section weights, required travel, cycle frequency, available power, ambient conditions and the proposed operator position. A risk review should define interlocks, emergency functions and safe maintenance states.

About Realjet

Realjet integrates hydraulic equipment with project-specific steel formwork and precast production systems. Our precast concrete production-line service connects mould operation with station layout, curing and material flow.

For fabricated brackets, machinery frames and made-to-drawing assemblies, Realjet also offers contract machinery manufacturing. Hydraulic and structural interfaces are reviewed together before manufacturing and workshop assembly.