Production of stairs in The United Kingdom
Flexcaster
Moulds for stairs with top and bottom landings, this formwork is suitable for producing stairs upside down (steps facing downwards)
An electric control panel with a remote control operates an electric linear actuator to adjust the distance between the individual steps. In this way, the tread of the steps is adjusted simultaneously. A second electric actuator is also provided to adjust the riser height of the entire staircase at once.
Consequently, both goings and risers can be adjusted and synchronised by 2 motorised movements.
As a standard feature, the goings are adjustable between 200mm and 320mm and the risers are adjustable between 150mm and 200mm. Usually, the width of the stair mould is 1,5m but this can be wider, up to 4m. In the wider moulds 2 stairs can be cast next to each other. Customers can choose any number of steps, but the number usually varies between 10 and 26. Long moulds with 20 steps or more can be used to cast 2 flights of stairs with a limited number of steps simultaneously. The Flexcaster can also be equipped with an electric tilting device to facilitate the installation of the reinforcement, the removal of the concrete stairs and the cleaning of the mould.
One side of the stair mould is equipped with a heightadjustable side panel. As a result of this height adjustment, the flight can vary in thickness between 120mm and 300mm. For non-tilting wide stair moulds, an extra adjustable side panel on the other side is an appropriate option. The stair mould includes 2 sets of landing equipment (top and bottom). The panel for the bottom landing is constructed as an extended first step element. The angle of the bottom landing panel can be manually controlled with great precision by means of 2 synchronised spindles.
The panel for the top landing sits on a carriage and can be inserted at every position after removing a few steps.
If the top landing carriage is set up at the rear of the mould, it will be linked to the last axle, thus travelling back and forth when the goings and risers are adjusted.
The angle of the top landing panel can be manually controlled with great precision by means of 2 synchronised spindles.
The most common feature of the steps is the one with the articulating front. These fronts are designed with a support plate which falls back 18mm, incorporating timber blocks and magnets. They can be used to fit 18mm plywood strips or 3mm metal plates onto which 15mm plywood strips are screwed. The steps with cutback and nose can be produced by using triangular magnetic chamfers which can overlap an opening of 40mm.
PLC Control
The operator uses a touchscreen to enter the riser and the going. Consequently, the PLC checks all safety sensors whether the mould is ready to be set, after which, the landings as well all the steps are adjusted according to the instructions of the operator. It takes only 3 minutes to complete a full cycle with nothing left to measure and the mould ready for use.
Other advantages of using a PLC are the higher safety and quality standards and the maintenance made a lot handier. A “cleaning button” sets the mould in its outer position, which makes it easy to clean the mould. Several sensors check if the side-form and pressure beam are fully closed and a visual control on the screen shows at what angle the top and bottom landings are set. This makes it easy to verify plans and design data, without the need for extra measuring equipment.
The option PLC includes that both landings have also an electric actuator that controls the angle and the position of these landings.
