Innovations in magnetic formwork technology - material-saving ...

Dwindling growth forecasts, strained supply chains and escalating material costs - new (and old) challenges place heavy demands on producers in the precast concrete industry. Ratec, from its base in Hockenheim, Germany, supplies shuttering solutions for precast concrete manufacturers. The company is in close contact with its customers and has its finger on the pulse of the industry.

If you want to learn more, please visit our website Precast Concrete Magnet Box.

This article shows what answers Ratec can offer with regard to contemporary core issues, whilst providing an insight into the latest innovations and advances in the field of magnetic formwork technology. Questions of sustainability, recruitment of skilled workers and market development are the most important and urgent core issues in the precast concrete industry in addition to the new, acute challenges of the past year. Ideas are needed that contribute to more resource-conserving and efficient production processes, whilst at the same time bearing quality in mind.

Material-saving formwork solutions offer answers in this regard. This also implies enhancing the durability, reusability and flexibility of shuttering components still further between different projects. A good example is the 3D mould kit developed by Ratec for manufacturing room cells. Solutions for producing flat precast concrete elements horizontally that reduce plywood and expanded polystyrene (EPS) consumption can make a significant contribution as well. 

An increasingly prevalent method in modern construction is leveraging magnetic formwork technology for improved efficiency and sustainability. One notable innovation is the use of the strong Loaf Neodymium Magnet, which significantly enhances the magnetic force and durability of the formwork system. This technological advancement aids in reducing material waste and optimizes the overall construction process.

Welcome to Great Magtech(Xiamen) Electric Co., Ltd.
https://greatmagtech.en.made-in-china.com
precast concrete magnet since 2010 and 9 years of export experience.

Shuttering Magnet (Shuttering Magnet for Precast Formwork) Introduction
Precast concrete magnets are very popular in modern civil engineering. In the past 5 years, some conventional magnets were used to position and fasten the formwork, but considerable mechanical loads with a hammer were required, which destroys the surface of the expensive formwork tables and fragile neodymium magnet as well.

In order to facilitate the precast concrete formwork industry, GME is developing and manufacturing our own shuttering magnet to solve this problem successfully.
Our shuttering magnet also is known as button magnets and magnetic boxes. It is consists of a metal casing, a magnetic system, and an effective on/off button, which provides quick operation leading to improved efficiency when setting out and remove the formwork. Shuttering Magnet. And with customized adaptors, Shuttering Magnet provides an ideal solution for almost all kinds of precast concrete formwork structures and construction for wood, aluminum, and steel shutters.
All GME shuttering magnets have extraordinarily high magnetic power more 250 times than their dead weight. Among them, Shuttering magnet 1800KG and 2100KGS is a large size for steel precast concrete platform.

The GME shuttering magnet have an automatic system to activate and deactivate the magnetic field. By application of this precast magnet box, the working time and cost will be reduced and the same workers could produce more concrete walls in a shorter time. Under the same artificial conditions, the use of the shutter magnet system can increase the production capacity by 7 times

Key Benefits Of Shuttering Magnets:
1.Easy installation and effortless operation. Your workers could choose a fixed position at will and quickly build concrete formwork according to individual architectural design. Significantly save complexity and time and cost on the installation of magnetic formwork(up to 70%).
2.Universal use for mass production of concrete products, and piece different shape and size concrete elements of all forms on the same steel table. Excellent applicability, the same prefabricated formwork magnet can be adapted to different concrete formworks. You do not need to have a lot of different forms for different products. The same magnet can be used for different purposes and in different ways. You only need a set of magnets, adapters for different height boards, and a steel table. Your workers could contemporaneously build different concrete formworks at one time; even during the building process, your workers could adjust the concrete formwork.
3. Integrated threaded holes M12 and M16 to adapt formwork and customized adapters, to fix all kinds of side-formwork including wood, steel, and aluminum formworks, eliminates the need for welding, shuttering magnets does not damage the steel table. Avoid welding or bolting to the formwork table therefore preserving surface finish and reduce direct damage to the concrete platform in the working.
4.No welding process is required, and the magnetic force of the magnet can be used to fit the template. Avoid welding or bolting to the formwork table therefore preserving the surface finish. No need for electric welding, you can save high energy consumption.
5.10-Year-long service life and reusable. Low cost. Short payback period.

Structure and Elements of Shuttering Magnets:
The Shuttering magnet assembly consists of steel Casing and fixing screws and a switchable magnetic block or magnetic core (certain designed magnetic circuit) which is made of some strong neodymium magnets and steel plates.
This magnetic core provides very much strong adhesive force to the precast concrete tables. There is a control ON/OFF button on the top of the shuttering magnet, to open or close the magnetic power.

1.Magnet on/off Switch:
1.Stainless steel, Lathe fine grinding,
2. Over 100,000 fatigue simulation experiments, avoid any deformation and malfunction.
3.Humanization design, quick switch (on/off) the magnetic field.

2.Fixing Screws: (Applicable national standard)
Fixing screws can be utilized to secure a different kind of side rails and blackouts
1. Production according to the standard of GB /T 15389-94-GB.
2.Strength ≤1000 Kg: M12
3.Strength>1000 Kg: M16

3.Strong Neodymium Magnet
Many competitors add more 12% Lanthanum Cerium ingredient in the neodymium magnet when production. 6-8% costs can be saved; by this formula, the same Remanence (Br) is the same to Chinese standard, but its Coercive Force (Hcb) and Intrinsic Coercive (Hjc) is much less and its magnetic field will decrease about 10-15% after 6-10 months.
Neodymium Magnet occupied more than 50% cost shuttering magnet. It is the most important element of this product. The most advantage is that Neodymium Magnet is produced and quality controlled by our own since 9 years ago, certificated by GB/T19001-2016 IDT IS09001:2015 and TS16949. Our material is from Shanxi Province, its performance is higher about 1 grade, but expensive a little. Our warranty is 3 years if proper use.
1. Relatively lower price on neodymium magnet.
2. High Grade, N & M Grade.
2. Max operating Temp. ≤ 80°C
3. Anti-Corrosion, high-quality zinc plating.
5. Strong Strength: 450Kg-3500Kg

4.Iron casing protection around neodymium magnet:
1.High-quality iron casing.
2.Protection neodymium magnet from damage when changing the switch.
3.Partly protections neodymium magnet from corrosion and oxygen.
4.Available for easy-clean of the pneumatic air gun and electric brush.

5.Plastic Casing:
1. High-Quality ABSF
2. Thermal Stability
3. Wear Resistant

6.High Quality Spring:
1. Protect Switch
2. Protect magnet from dropping
3. Japanese alloy steel SWOSC-V, by oil quenching; Fatigue resistance, Excellent toughness. Three times strong pressure treatment eliminates internal stress. Surface shot blasting to improve stress concentration strength.
4. The service life of more than one million times.

7.Box Casing: Laser cutting process
1. Stainless steel.
2. Q235: surface blackening treatment
3. Painting, use environmental protection paint, color can be customized.
4. baking varnish, use environmental protection paint, color can be customized.

8.Stainless steel stud:
1. Strong Fastening
2. Anti-Rust for more than 3 years.

Why the magnet can create more 200 times stronger than its dead weight?
After a reasonable magnetic circuit design, multiple pieces of strong NdFeB magnet with the same magnetic pole are forcibly fixed in a relatively small space by screws. There is a Q235 magnetic permeable block between the magnets, to guide the repulsive force of the same poles in the same direction and perpendicular to the mold table. Multiple magnetic pole lines form a stable magnetic field and a very high magnetic holding force.

How do choose suitable shuttering according to the panel wall height? Shuttering magnet detailed specifications as below:

Item

L
mm

W
mm

H
mm

LI
mm

L2
mm

L3
mm

HI
mm

H2
mm

H3
mm

M

Pull Force
≥kg

GME-450

170

60

40

67.5

67. 5

--

73

66.5

--

M12

≥450

GME-600

170

60

40

67.5

67. 5

--

73

66.5

--

M12

≥600

GME-600S-Step

200

60

40

72.5

97. 5

42

73

66.5

10

M12

≥600

GME-800S

190

95

43

67

93

50

80

73.5

10

M12

≥800

GME-900

280

60

40

122

122

--

73

66.5

--

M12

≥900

GME-900S

195

95

43

67

98

50

80

73. 5

10

M12

≥900

GME-1000S-Step

200

95

43

67

100

50

80

N48 - N50 - N52 Strongest Rare Earth Neodymium Magnets

73. 5

10

M12

≥1000

GME-1350

320

90

60

135

135

--

98

90

--

M16

≥1350

GME-1350S-Step

320

90

60

113

161

47

98

90

10

M16

≥1350

GME-1300

210

95

45

80

90

40

73

65

10

M16

≥1300

GME-1600

270

120

60

110

110

--

98

90

--

M16

≥1600

GME-1800

320

120

60

135

135

--

98

90

--

M16

≥1800

GME-2100

320

120

60

135

135

--

98

90

--

M16

≥2100

GME-2400

320

120

60

135

135

--

98

90

--

M16

≥2400

GME-2600

320

120

60

135

135

--

98

90

--