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CLI-approved steel moulds for Accropode concrete armour units, 2 to 16 m³: faceted skins, stiffener ribs and machined split flanges, so every unit casts the same and interlocks on the breakwater.
Scroll: the camera moves to each part in turn and ends on the exploded view. Drag to turn it round yourself.
01 / 09
Accropode units interlock on a breakwater, so every one has to be the same shape. Few fabricators in India can make the moulds. We made a set for ITD Cementation, designed, built and delivered in one month, and earlier sets for the JSW jetty at Paradeep.
Scroll to see how it is built · drag to turn it round
02 / 09
The mould parts on the mid-plane of the unit. Each half carries 2 horns on each side and 1 nose. Skin plates are cut on the fibre laser to every facet and welded to CLI tolerances.
Used here for: 2 half shells
In 2024 we were the only buyer of Deratech’s 20 kW, 12 m laser.
03 / 09
Each half has 24 pyramid pockets pressed into the skin: 5 on each horn and 4 on the nose tip. They cast the studs that make the units grip each other.
04 / 09
Angle bands round the shell and ring frames round each nose hold every face flat against the pressure of wet concrete.
05 / 09
Flat-bar flanges run round the whole outline. Clamp bolts with wing nuts close the joint at set clamping points, and locators centre the halves for every cast.
Used here for: Halves that close the same way
06 / 09
Each nose ends in a removable panel plug. A screw jack on the plug pushes the half off the cast unit. A hatch on top of the nose lets the vibrator in.
07 / 09
U-bolts on the upper horns lift each half. Props under the noses and skids under the lower horns keep the mould steady while it fills.
08 / 09
The concrete armour unit: inside the closed mould, and beside it as it leaves, with 4 horns, 2 noses and 48 studs.
09 / 09
Half shells, stiffeners, flanges, bolts, plugs, jacks and props.
A cast unit lifted clear of the mould in our works.
A row of finished armour units, ready for the breakwater.
We fabricate to your drawings and prove the fit in our own bay before anything ships. Open any line for the detail.
Talk to an engineerWe fabricate to your design, from plate to a packed container. An engineer will tell you honestly how we would build it.
