Good cake, bad cake

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Good cake, bad cake

Do you remember those days in childhood when the sun always shone, time moved slowly, and you had the best molds in the block? Mixing just the right amount of sand and water, packing it tightly in the mold with your new spade, and then the final moment of truth awaited. Carefully, you would pick up the mold and turn it over on the ground, holding your breath for a split second. Would today be the day for a perfect cake?

At Elematic, we pursue perfection in everything we do and we want the same for our customers. High quality concrete elements with smooth surfaces and flawless edges require excellent skills and equipment, and this begins with the very foundation of precast manufacturing: molds and casting beds. Rimera Oy is part of the Elematic Group and has been making top quality steel-structured molds for the precast concrete industry since 1980. The Rimera range of molds is extensive and covers all types from hollow-core slab casting beds to battery molds, table molds, TT-slab molds, beam molds, and last but not least, molds for making prestressed concrete railway sleepers. Gone are the days of wooden sleepers that needed to be impregnated with toxic materials and which became hazardous waste when they started to deteriorate. A new era has begun and every day is a perfect-cake-day when you have perfect molds!

Rocketing growth

Rimera's growth has been accelerating since 1999, and from 2004 onward it has been simply rocketing! "Over 24 km of hollow-core casting beds left our factory in 2007", says Rimera's Managing Director Antti Lahti. These hollow-core beds are commonly used in the precast industry throughout the world. Made of high quality materials specially developed for mold structures, they also make for a simply smashing export product! Namely the 10 x 12 meter molds fit like a glove into a shipping container. "If the container is fully packed, maximum advantage is gained and the molds can be cost-efficiently shipped to Australia, if need be", explains Mr Lahti. Of all Rimera-made products, 96 % are exported.

Molds for walls - inside and out

Battery molds are traditionally used in the production of non-insulated reinforced concrete elements, such as load-bearing partition walls for multi-storey buildings. For your insulated outer wall sandwich panels, you need superb quality tilting tables. These are always manufactured according to the customer's specifications. Just tell us the required table size and the type of side-closures, as well as the method of vibrating, and we will deliver your table of choice. If you manufacture beams, whatever the size, shape, and length they may be, we have the molds. Although often used to make pre-stressed beams in plants where permanent anchorage is not available, these molds are also useful for making individual beams as well as beams that do not need to use the full stressing line.

Airplane-precision for that extra quality

"Right now, perhaps the most exciting product in our workshop is the railway sleeper mold", says Mr. Lahti. "It is the most challenging and exacting mold, for which the tolerances are so low as to be non-existent!" The fact that every country has its own particular size of railway sleeper is just fine and dandy, but the sleepers need to be accurate to the millimeter, no lapses allowed. But this challenge has only served to bring out the best in Rimera. "We have gained vast experience from various projects over the years, and this knowledge has helped us fine-tune our methods to the level of airplane-precision", Mr. Lahti states.

High-tech and skill hand in hand

Despite the extreme accuracy of the measurements, railway sleepers are bulk products and the molds need to be long-lasting even when used in continuous shift work. No problem: the molds are a welded steel structure made of laser-cut pieces, as is the case with all Rimera molds. Top quality trimming machines are used. In the past, the mold parts were welded together on the inside, but today, this is no longer necessary. The parts are jig welded to the mold cartridge, the parts are so exact that it enables welding from the outside. Thus, no grinding of the inside is required either, which significantly cuts down on working time.

Less work means savings

3D-modelling enables exact drawings to be made, leaving nothing to guesswork. This also makes the test mold more precise, and it can be easily adjusted in the 3D-modelling program, if required. Improving cost-efficiency is an objective in every project. Savings can seldom be made in the use of materials, but the number of work hours can be reduced, which is achieved by improving the planning and design stages. Rimera has high-tech aids as well as the ability to use them. With drawings that show what needs be done down to the smallest detail, the "king-of-the-workshop" is not always needed to turn out perfect end results; others can do it equally well.

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