Retrofitting is an Attractive Alternative to Purchasing New Shuttering Profiles or Pallets

Shuttering profiles and pallets in precast concrete production are critical to the quality and surface finish of the final product. However, after prolonged use (e.g., over 20 or nearly 30 years), these components will show signs of wear.

Manifestations and Impacts of Wear:

•  Grooves or unevenness on the pallet surface.
• Deformation or damage to side rails.
• Overall distortion of the components.
• Surface damage may reduce the magnetic force of embedded magnets.

Maintenance and Retrofitting:

•      Purpose:

Retrofitting is an effective way to restore old equipment to a near-new condition. It aims to repair wear and damage and restore the flatness and surface quality of the shuttering to match or approach the level of new ones, ensuring continued high-quality production. Retrofitting also addresses issues such as reduced magnetic force caused by surface damage.

• Advantages:

◦ Retrofitting serves as an attractive alternative to purchasing new shuttering profiles or pallets.
◦ Retrofitting is typically more economical than replacement. For example, pallet repair costs approximately one-third of replacement costs, though actual savings depend on the pallet’s condition. Johannes Bürkle expressed satisfaction with their pallet repair results, stating that the cost compared to replacement was "truly incomparable."
◦ Retrofitting enhances product quality.

• Retrofitting Process (Using Pallets as an Example):

◦ Sandblasting.
◦ Straightening deformed pallets.
◦ Surface grinding.
◦ Repainting.
◦ Refurbishing or replacing side rails as needed.
◦ Repairing steel plate damage via welding.
◦ Comprehensive surface grinding of shuttering using specialized machinery.
◦ Adding alignment points for newly installed formwork robotic systems.

• Implementation: To avoid disrupting production, retrofitting can be conducted in batches. Clients can send a truckload of pallets or shuttering profiles to a retrofitting service provider and retrieve refurbished units for reintegration into the production line. Many clients have successfully revitalized aging shuttering systems or pallets using this approach.

• Professional Services: Some well-known equipment and machinery manufacturers not only provide new systems but also repair services. With decades of expertise in both new equipment and retrofitting, they are specialists across multiple domains. In 2017 alone, retrofitted over 100 pallets. Clients such as Betonwerk Bürkle attest that retrofitted pallet surfaces are "as good as new." Johannes Bürkle emphasizes that to ensure final product quality, they exclusively source branded products and premium services from trusted partners and suppliers.

Final maintenance and cleaning of these parts helps address wear issues and maintain quality.

Maintenance and Cleaning

Regular cleaning is a key aspect of maintaining formwork systems. This often involves removing concrete residues and applying release agents. Modern precast plants often incorporate automated cleaning processes.

• A pallet cleaning device scans the pallet, and removes shutters, magnets of mounting sleeves, and electric installation parts, storing them automatically. Concrete remains are then transported away by a rubbish conveyor belt.

• Some cleaning stations use disk and roller brushes for conventional cleaning of shuttering profiles.

• After cleaning, a release agent is applied, sometimes automatically through spray nozzles or an integrated spray unit with rotating nozzles. Automated application can be precise, applying the agent only where concrete will be placed.

• Pallet cleaners with rotating brushes and steel scraper units free surfaces from adhering concrete residues and adhesives.

• In some systems, a multifunctional trolley cleans and oils shuttering surfaces, while others have a pallet cleaning unit that removes concrete residues from the surface and edge shuttering using a spatula and brushes.

In summary, wear and tear on shuttering profiles and pallets is inevitable. However, through professional retrofitting services, their functionality and quality can be fully restored, delivering significant cost savings while enabling phased implementation without production downtime.