Movable formwork designed around the production process

Movable hydraulic formwork combines a fabricated steel mould, hydraulic operating functions and a guided travelling system in one project-specific production solution. Instead of treating the mould as a fixed installation, the system allows the formwork or mould-carrying platform to move between defined work areas for preparation, reinforcement, concrete placement, curing, demoulding and release.

The configuration is developed around the precast element, required geometry, casting sequence, target cycle and available factory layout. Hydraulic functions can be assigned to opening, closing, positioning, adjustment or demoulding according to the approved mould concept. The travelling arrangement, rails, drive method and station interfaces are then coordinated with the wider production line.

Key product characteristics

  • Hydraulic operation for controlled mould movement. Hydraulic cylinders and control groups can support selected opening, closing, alignment and demoulding actions. The operating sequence is configured for the actual component and mould structure.
  • Movable, station-based production. A rail-guided mould carrier can transfer the formwork through planned production and curing positions, helping organise labour, fixed equipment and process tasks by station.
  • Project-specific steel structure. Load paths, plate thicknesses, stiffeners, supports and connection details are engineered for the approved component geometry, concrete pressure and handling method.
  • Repeatable positioning. Mechanical stops, reference points, locking devices and adjustment interfaces can be incorporated to support consistent setup across repeated casting cycles.
  • Production-line integration. The formwork can be coordinated with reinforcement work, concrete distribution, vibration, curing chambers, cranes, transfer equipment and production controls.
  • Practical access and maintenance. Working platforms, operating positions, hose routing, inspection points and maintenance access are reviewed as part of the equipment layout.
  • Safety defined with the operating sequence. Travel limits, interlocks, emergency stops and operator procedures are selected according to the final mechanism, control scope and site conditions.

Typical applications

Movable hydraulic formwork is suitable for precast operations where a mould needs to travel between production stages or where fixed stations must serve multiple moulds. Typical applications include:

  • bridge girders and beams;
  • segmental or box-shaped concrete elements;
  • U-shaped, T-shaped and other elongated precast components;
  • project-specific infrastructure elements with repeated geometry;
  • new precast factories using a station-based production concept;
  • existing plants that need to reorganise mould movement, curing or workstation utilisation.

The final formwork arrangement depends on component dimensions, reinforcement congestion, embedded items, concrete placement method, curing process, lifting plan and required cycle time. Realjet therefore confirms the planning basis before fixing the hydraulic and travelling configuration.

Information required for a project proposal

To prepare a suitable concept, the project team should provide available component drawings, dimensional tolerances, estimated concrete pressure, reinforcement and embedded-item details, daily or shift output targets, curing method, factory layout and utility conditions. Information about crane coverage, rail routes, maintenance space and interfaces with third-party equipment is also important.

Based on these inputs, Realjet can define the mould division, hydraulic functions, travelling method, station arrangement, control boundary and delivery scope. The proposal can cover an individual movable formwork system or integration into a complete precast concrete beam factory.

About Realjet

Realjet develops project-specific equipment for precast concrete production and infrastructure construction. Our work connects process planning, mechanical design, steel fabrication, hydraulic integration, workshop assembly, installation support and commissioning around the customer's production objective.

For projects that require fabricated frames, mould structures, machined interfaces or other made-to-drawing equipment, Realjet also provides contract machinery manufacturing. This combined engineering and manufacturing capability allows the formwork, moving system and production-line interfaces to be reviewed as one coordinated scope.

Send Realjet the component drawings, production target and available layout to begin a technical review of the movable hydraulic formwork concept.