Next-Generation Sleeper Production with Automated B70 Carousel System in Romania

Construx-Weckenmann announces the successful commissioning of a fully integrated carousel-based production system for prestressed railway sleepers in Romania. Developed to support the increasing demands of modern rail infrastructure, the facility is engineered to deliver high-volume, high-precision manufacturing of Type B70 sleepers. With a strong emphasis on automation and scalability, the new system brings together mechanical excellence and intelligent control to create a reliable, future-ready production line.

Engineered for Productivity: 189,000 Sleepers per Year

The heart of the installation is a high-capacity carousel plant equipped with 300 quadruple sleeper moulds and 20 synchronized workstations. The circulation of moulds is seamlessly managed to ensure optimal cycle times and minimize idle phases. To support curing requirements, the system includes four tunnels with a rope pull system, each housing multiple positions, resulting in a total of 300 mould capacity within the curing zone. This enables uninterrupted production and supports year-round operation under controlled, consistent conditions.

Key Performance Metrics

• Annual production capacity: ~189,000 sleepers
• Output per shift: 756 sleepers
• Operating schedule: 1 shift per day, 250 days per year
• Facility dimensions: 73 m (L) x 23 m (W)

Automated Workflow for Scalable Output

The sleeper production process is fully streamlined through an automated and modular workflow. A dual-direction mould transport system, operating longitudinally and transversally, allows continuous mould circulation through all production stations. Mould preparation is handled with manual oiling and placement of built-in parts, providing flexibility and precision in set-up. Rebar placement is facilitated by a semi-automated system that ensures accurate positioning while significantly reducing manual workload.

Prestressing is managed through fully automated tensioning and detensioning systems, enabling consistent mechanical performance and compliance with railway specifications. Once reinforcement is in place, concrete is introduced using a 4-screwed concrete spreader, designed for even distribution and minimal waste. To ensure optimal compaction, the MagVib station applies high-frequency vibration, eliminating entrapped air and enhancing density within each sleeper.

After compaction, moulds are queued for curing using a manually operated stacking crane, offering flexibility in load sequencing. The curing process itself is carried out in closed, unheated chambers that maintain stable environmental conditions to support proper hydration and strength development. Upon curing, the system transitions into a fully automated transport, turning and demoulding process, ensuring a seamless and efficient progression through the final stages of production.

Digital Control with WAvisionplus: Transparency & Optimization

The full production cycle is monitored and managed through WAvisionplus, a digital control platform that provides real-time oversight, data logging and operational analytics. This system enables traceability of every production step, offering visibility into KPIs and actionable insights for plant management. By integrating automation with digital intelligence, the plant delivers consistent product quality while maintaining operational efficiency.

Future-Proofing Railway Precast Solutions

The Romania project demonstrates Construx-Weckenmann’s ability to deliver scalable, technically sophisticated solutions tailored to the evolving demands of the precast concrete industry. As railway networks expand and modernize, this carousel system sets a new benchmark for precision and productivity in sleeper manufacturing - supporting infrastructure development with reliability and forward-thinking engineering.