Innovative solutions for prestressed concrete elements

With a strong reputation in the precast industry, Construx-Weckenmann specializes in designing and manufacturing advanced steel moulds and auto-reactive casting beds tailored to meet the demands of modern precast production. In close collaboration with the customer, Construx-Weckenmann tries to find the most appropriate system which is in accordance with all technical specifications, which fits the customers’ budget and which copes with the dimensions and numbers of prestressed elements the customer wants to cast. Being ‘Top of mind’ in solutions for prestressed concrete elements, Construx-Weckenmann became a leading supplier for many of the major European precast manufacturers. Recently, Construx-Weckenmann supplied several different moulds and casting beds to a number of precast manufacturers all over the world.

Auto-reactive beds

Construx-Weckenmann supplies state-of-the-art auto-reactive beds, which enhance prestressed beam production by offering:

• Built-in prestressing anchors, eliminates external tensioning structures, optimizing space and workflow
• High precision and consistency, ensures correct prestress line positioning for uniform quality
• Modular and adaptable systems, suitable for various beam sizes and prestressing configurations
• Increased productivity, reduces setup time and enables continuous, high-volume manufacturing

Prestressed beam moulds

The Construx-Weckenmann prestressed beam moulds are engineered for precision, durability, and efficiency, ensuring that prestressed beams meet strict structural and dimensional requirements.

These moulds are built with:

• Robust steel construction, designed to withstand high tension forces from prestressing
• Customizable formwork, adjustable moulds to accommodate different beam dimensions and shapes
• Smooth and efficient demoulding, innovative designs that allow easy stripping of beams without damaging edges or surfaces
• Long service life, high-quality materials and craftsmanship ensure repeated use with minimal maintenance

France: Self-reacting 4-gang mould

This 36m long mould is designed for manufacturing trapezoidal beams with a maximum height of 700mm and a tapered width of 220mm to 280mm. Its capacity is 8n° prestresses beams of 18m long with 192T prestressing force per beam

Key features:

• The chassis is designed to withstand prestressing forces
• No foundation work required
• Capable of producing 2 trapezoidal beams (18m each) in four rows
• Live-end (800T) equipped with active stressing head, horizontal radiator block and single acting hydraulic cylinders (2 x 400T) with a stroke of 100mm
• Dead-end (800T) equipped with passive stressing head and a horizontal radiator block
• A free space of approximately 600mm between the radiator block and the formwork is provided, facilitating the cutting of strands

Hungary: Flexible and modular precast production system for prestressed beams

Construx-Weckenmann provided a flexible and efficient precast production system for this Hungarian precast company, including 9 self-reacting casting beds designed for various prestressed beams (rectangular, inverse-T, I-girders, IV-roof, and T-roof). The modular system includes 6m long live-end and dead-end units, with 12m long bed parts in between, all secured with sliding foot plates. The foot plates of the bed parts are fixed by means of mechanical anchors, the foot plates of both live-end and dead-end are fixed onto the factory floor with micropile grouting anchors. The beds have a 50mm hole increment pattern for easy side mould attachment, with 300T, 500T and 600T capacity options. The system uses hydraulic rams (4 per live-end), adjustable to accommodate beams up to 2000mm high.

Three types of adjustable girder moulds were supplied, covering a range of beam types and heights. These moulds are modular, with lengths of 6m, 4m, 3m, 2m, and 1m, allowing for flexible production and future expansion. Rectangular and inverse-T beams are made using a combination of panels with varying heights (400mm, 600mm, 800mm). For I- and IV-beams, vertical posts and adjustable box-out panels form recesses, while T-roof beams use a similar mould system with adjustable flanges

Belgium: Prestressing beds with different types of adjustable beam moulds

This Belgian precast company increased its capacity with self-reacting and non-reacting beds and several adjustable moulds for girders, purlins, IV-beams and bridge beams:

• 1 Self-reacting 1000T / 250Tm bed for beams and girders, 62m long
• 2 Non-reacting beds for beams and girders, 125m long
• 2 Sets of adjustable moulds for I-beams, 20m and 32m long
• 1 Set of adjustable moulds for inverted T-beams, 20m long
• 2 Sets of adjustable moulds for IV-beams, 32m and 48m long

France: Several projects with single and double-gang hydraulically operated self-reacting prestressing moulds

These installations are designed for the production of prestressed concrete beams, with a length of up to 40m and an adjustable width between 300mm and 600mm. Construx-Weckenmann designs these prestressing moulds as self-reacting beds, this means that the beds take all the prestressing forces, and no abutments are required. The mould sitting on the bed is non-reactive and fully hydraulically operated. The live- and dead ends are capable of absorbing the forces generated by the 500T prestressing rams. The live-end features two fixed-position cylinders with a hydraulic clamping system to transfer forces to the self-reactive bed. The structure allows for free longitudinal movement of the bed during the process, and the installation is divided into four sections that are securely bolted together to ensure proper force transfer. The Construx-Weckenmann two-gang moulds have two pockets which can be used independently.

Indonesia: Stationary production plant for prestressed floor slabs

A product is only as good as the sum of its properties and its quality depends on the technology used to produce it. Construx-Weckenmann is not only a ‘top of mind’ mould manufacturer but develops and builds also state-of-the-art machines to produce precast concrete elements. All the equipment along the entire process chain is manufactured using the latest technology and compatible with each other, so that the individual parts fit together perfectly. The result of this sophisticated technology: efficient production of top-quality products from A to Z.

In this Indonesian production facility, Construx-Weckenmann installed prestressing beds for floor slabs and all related equipment:

• 6 beds of 120m x 2,4m with hinged side-forms for 3 thicknesses
• Prestressing abutments
• Flying bucket
• 2 concrete spreaders with poker vibrators
• Transport wagon for the floor slabs
• 2 trolleys for stop-ends and magnets
• Cleaning, oiling and strand pulling machine
• Strand cutting saw

Canada: Stationary production plant for double walls, insulated walls and floor slabs

Construx-Weckenmann installed 6 self-reacting prestressing beds with each a 240T stressing capacity: 5 beds of 100m long and 2,38m wide, and 1 bed of 100m long and 4,60m wide. The side-forms on the beds are hydraulically hingeable for easy demoulding and cleaning. These side-forms are also fully hydraulically adjustable at 5 different heights: 205mm, 230mm, 255mm, 280mm and 305mm.

Construx-Weckenmann delivered also all required machinery:

• Strand cutting saw
• Cleaning and oiling device
• Plotter trolley
• Shutter placement machine
• Workplace system trolley
• Reinforcement and mesh trolley
• Trolley for strand pulling
• Insulation material trolley
• Concrete spreader with poker vibration and screed: 2n°
• Power floating device
• Rib forming machine / surface roller
• Tarp cart
• Side shifter with turning device
• Run-off straddle carrier

Shaping the Future of Concrete

With decades of expertise, Construx-Weckenmann is a trusted partner to precast manufacturers, delivering efficient and high-performance moulds and auto-reactive beds. Driven by engineering excellence, Construx-Weckenmann tailors every solution to meet the unique needs of the clients, ensuring optimal outcomes in the production of precast elements and consistently exceeding expectations.

“At Construx-Weckenmann, we don’t just manufacture equipment, we forge long-term partnerships. Our team’s commitment, creativity and experience are the foundation of the innovative, turnkey solutions we provide for the full spectrum of precast challenges. Our mission is clear: to be more than a supplier by becoming a reliable and collaborative ally in our clients’ success”.