complete and brand-new precast factory in hungary

PRECAST CONCRETE ELEMENTS

CPI – Concrete Plant International – 5 | 2020 www.cpi-worldwide.com204

Market Építő Zrt., one of the major Hungarian construction

companies, based in Budapest and specialised in the de-

sign and construction of industrial, public, commercial,

and logistic facilities, recently launched a new company

in the east of Hungary. Prebeton Zrt. will assist the Market

Group as a precast concrete prefabrication and rebar plant.

Market Group requested Belgian manufacturer of machin-

ery Construx to design a complete package of moulds,

machines and accessories to produce precast walls, rein-

forced and prestressed beams, filigree slabs and stairs.

Prebeton, whose new plant in Erdőtelek, has just been inau-

gurated, is engaged in the production, assembly, and machin-

ing of precast reinforced and prestressed concrete structures.

Its services include design, manufacture, delivery and assem-

bly; enabling it to provide quality construction in a full range

of structural projects. To develop their precast production,

they requested Construx to design a complete package of

moulds, machines and accessories to produce precast walls,

reinforced and prestressed beams, filigree slabs and stairs.

Construx supplied Prebeton with the following equipment:

• 1 Flexcaster electrically adjustable stair mould

• 1 hydraulic tilting table

• 2 fixed tables

• 6 Multibat beam moulds

• 3 self-reacting prestressed filigree casting beds

• 6 self-reacting prestressed beam casting beds

• 3 different types of adjustable and modular side-shutters

for prestressed beams

• 5 precast concrete buckets

• all magnetic accessories and side-forms

Flexcaster electrically adjustable stair mould

This horizontal electrically adjustable stair mould with

24 steps is suitable for producing stairs upside down (steps

facing downwards) with one or two landings. An electric con-

trol board unit with remote control operates 2 horizontal elec-

Complete and brand-new precast factory in Hungary

Construx, 8531 Hulste, Belgium

Aerial view of the new Prebeton factory

Overview of a part of the factory

06b-Precast_180-211_en.qxp_Layout 1 03.09.20 10:18 Seite 204

Precast Moulds& On-Site Formwork

Hazebeekstraat 11Hulste, Belgium+32 56 72 47 93

[email protected]

Hulste (B)Genk (B)Roeselare (B)Boortmeerbeek (B)Veenendaal (NL)Bucharest (RO)


www.cpi-worldwide.com CPI – Concrete Plant International – 5 | 2020

tric actuators in order to adjust the distance in between the

individual steps. The same electric unit also operates 2 vertical

electric actuators, which adjust the angle between the steps.

Consequently, both going and rise are electrically controlled.

The net width of the mould is 2,500 mm and the maximum

length of the landings is 1,500 mm. The risers can be adjusted

from 150 mm to 200 mm and the goings can be adjusted

from 200 mm to 320 mm. The steps have incorporated timber

parts and magnets. So, cut to measure 21 mm thick ply fronts

can be nailed straight onto the risers or 18 mm ply fronts can

be bolted onto individual 3 mm thick laser cut steel plates

which can be locked onto the magnets. The mould is

equipped with a height-adjustable and articulating panel on

one side. The stair mould includes two sets of landing equip-

ment (top and bottom). The bottom landing panel is con-

ceived as an extended first step and can be electrically posi-

tioned at the right angle. The panel for the top landing sits on

a carriage and can be inserted at every position after remov-

ing a step. If the top landing carriage is set up at the rear of

the mould, it will be linked to the last axe, thus travelling back

and forth when the goings and risers are electrically adjusted.

The angle of the top landing panel can be controlled manu-

ally with great precision by means of two manual spindles.

A hydraulic group controls a hydraulic tilting device to facili-

tate the installation of the reinforcement, the removal of the

concrete stairs and the cleaning of the mould. Easy to install

1,000 kg strong Construx box-magnets, equipped with a steel

side flange, serve to fix the side-forms.

Hydraulic tilting table

This Construx tilting table has a length of 12 m and a width of

4 m and is equipped with one single steel sheet with a thick-

ness of 8 mm, without any welds or joints. The plate is

stripped, sandblasted and polished with Scotch-Brite and has

a tolerance of +/-1,5mm on 3 m length. The top structure is

subdivided into a top pallet and a tilting frame, with vibration

absorbers fitted in between the two. This gives the table a

very smooth and equal vibration pattern with no loss of

Flexcaster stair mould




energy in the frame or in the ground. The tilting frame is tilted

by means of two telescopic cylinders; these rams are driven

by means of a hydraulic aggregate with two pumps in order

to synchronize the stroke of the two cylinders. The pallet and

the frame are not structurally connected. The frame is con-

nected with hinges onto two stable and fixed ground beams.

These ground beams accommodate the cylinders and are

equipped with floor supports. Each of these floor supports

has also a rubber absorber. The table has a tilting angle of 80°

and can carry a load of 700 kg/m². The maximum overall tilt-

ing capacity is 26 T and the total load capacity without tilting

is 35 T. The table has one 12 m long and two 4 m long side-

forms with an incorporated timber top-profile. Each side-form

can be manually and steplessly adjusted in height from 100

mm to 300 mm. These forms are bolted against the side of

the table and a 90° angle can easily be adjusted. The tilting

table is equipped with ten 14 kN high-frequency vibrators

which can be regulated by means of a frequency converter.

Fixed tables The two individual 12 m long and 7 m wide fixed tables are

each divided into two separate tables of 12 m x 3,5 m. These

separate tables are, same as the tilting table, equipped with

one single steel sheet with a thickness of 8 mm, without any

welds or joints. The plate is stripped, sandblasted and pol-

ished with Scotch-Brite and has a tolerance of +/-1,5mm on

3 m length. The steel structure is a top pallet which sits on

steel feet, with vibration absorbers fitted in between the two.

This gives the table a very smooth and equal vibration pattern

with no loss of energy in the frame or in the ground. The ta-

bles can carry a maximum load of 700 kg/m². Each 12 m x 7

m table has one 12 m long and four 3,5 m long side-forms

with a steel top-profile. Each side-form can be manually and

steplessly adjusted in height from 100 mm to 300 mm. These

forms are bolted against the side of the table and a 90° angle

can easily be adjusted. Each table is equipped with sixteen

14 kN high-frequency vibrators which can be regulated by

means of a frequency converter.

Multibat beam moulds with a total capacity of 576 m per day

Construx also supplied six Multibat beam moulds, of 16 m

length each, to Prebeton. These multi-pocket battery moulds

have manually movable panels and are used to make precast

reinforced concrete beams, so, an overhead crane is only re-

quired when putting in the reinforcement cages and taking

out the concrete elements the next day. This type of formwork

system is also suitable for producing columns, lintels and any

other type of long concrete element. The battery moulds are

composed of mobile steel panels with a 6 mm steel sheeting

on one or on both sides. These movable panels are set and

fit opposite to a fixed panel. The Prebeton Multibats have six

pockets and they consist of a fixed middle open panel with

incorporated working platform, four intermediate double-

sided panels and two end panels. The 16 m long panels are

Hydraulic tilting table Fixed tables and Multibat beam moulds

Multibat beam mould



fitted onto eight 8 m long transverse double steel profiles.

Each set of profiles is equipped with six feet. Two of these sets

are equipped with flat steel guide rails for the manually mov-

able panels to roll on. The panels can be fixed by means of

tie-bars at the top and spindles at the base. The panels are

750 mm in height on the left side and 1,250 mm in height on

the right side of each Multibat. A spindle system with a wheel

is integrated in the frame of the panels in order to obtain the

manual adjustment and fixation of the panels on the rails

below. Flexible 250 kg Construx PU-magnets serve to fix the

stop-ends.

Self-reacting casting beds for the production of 1,200 mm wide prestressed filigree slabs, with a total capacity of 132 m² per day Each of these three Construx self-reacting casting beds con-

sists of a 36,5 m long bed, an active stressing head called the

live-end, a passive stressing head called the dead-end and a

set of four hydraulic cylinders. All self-reacting casting beds

(for filigree and beams) are operated by means of two mobile

hydraulic groups. The useful width of the beds is 1,200 mm

and the beds have a prestressing capacity of 300 T each. Both

sides of each bed have a 140 mm high tapered fixed side

form with a 10 mm x 10 mm triangular chamfer at the bottom.

The beds come in modular parts and all these bed parts as

well as the live-ends and the dead-ends are held onto the fac-

tory floor by means of sliding foot plates, so the entire bed

can slightly move back and forth. 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 fac-

tory floor with micropile grouting anchors. The overall bed ca-

pacity is defined by the maximum linear force (300 T), which

is in accordance with the individual strengths of each strand.

The active and passive heads are equipped with an open line

to guide the strands. The active head is equipped with two

hydraulic cylinders, each with a 160 T capacity and a 300 mm

stroke.

Flexible self-reacting casting beds for the production of a wide range of prestressed beams, with a total capacity of 219 m per day Prebeton insisted in getting a flexible and affordable solution

for the manufacture of their different types of prestressed

beams: rectangular beams, inverse-T beams, I-girders, IV-roof

girders, T-roof girders and so on. Prebeton also preferred to

invest in moulds and machines, rather than to invest in foun-

dation works for abutments, which would limit the flexibility

of a future expansion. To meet these requirements, Construx

suggested six individual lines with a net length of 36,5 m

each. Construx designed the prestressing lines as self-react-

ing beds, this means that the bed takes all the prestressing

forces and no abutments are required. All six casting beds are

Self-reacting filigree casting bed




conceived as a modular setup with a live-end and a dead-end,

both with a 6 m long bed part connected to the end structure.

In between both ends, the bed is assembled with 12 m long

modular bed parts. All bed parts as well as the live-end and

the dead-end are held onto the factory floor by means of slid-

ing foot plates, so the entire bed can slightly move back and

forth. 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 grout-

ing anchors. So, the modularity consists in having a live-end

with a 6 m bed, a dead-end with a 6 m bed and several 12 m

long bed parts fitted in between. This setup allows Prebeton

to be extremely versatile and flexible for future projects. To

be able to accommodate a wide range of prestressed beams,

the beds are 36,5 m long and 1,500 mm wide, allowing for a

useable width of 1,000 mm. A repetitive pattern of holes

along both sides of each bed allows the fixation of different

types of girder moulds. It is a 50 mm increment pattern which

is very precisely laser cut every 1,000 mm on both sides of

each bed. The 50 mm modulus holes serve to bolt down the

bottom of the moulds. Three of the beds have a 300 T capac-

ity, the other three have a 600 T capacity. The capacity of the

active heads is defined by that linear maximum force maxi-

mum (300 T/600 T), which is in accordance with the individual

strengths of each strand. The capacity of the active head is

also defined by a moment of force (140 Tm), created by the

distribution of the different strands on various heights. The

sum of all individual moments of force of each strand cannot

exceed this 140 Tm capacity, which corresponds to 90 % of

the forces at a height of 300 mm and 10 % of the forces at a

height of 2,000 mm. Each of the six live-ends is equipped with

a set of four single-action hydraulic rams with a 300 mm

stroke. The three 300 T beds have two cylinders with a 150 T

capacity at the bottom and two cylinders with a 50 T capacity

at the top. The three 600 T beds have two cylinders with a 300

T capacity at the bottom and two cylinders with a 100 T ca-

pacity at the top. One of the mobile hydraulic groups with

controls operates all the live-ends. The height of the heads is

2,000 mm, which corresponds to the maximum height of the

beams to poor. All live-ends as well as all dead-ends are

equipped with very thick and solid steel pattern divider

plates. The position of the holes in these plates is according

to Prebeton’s standards and are as high as 2,000 mm above

the bed surface.

One of the great advantages of these self-reacting beds is the

speed of installation. From scratch, it didn’t even take two

weeks for the Construx technicians to have the three filigree

and the six beam casting beds completely installed and com-

missioned. Up to two weeks before commissioning, the cus-

tomer can use the same facility for other purposes. When

choosing the abutment type prestressing lines, the installation

may easily take more than a couple of months for civil works.

Works to be carried out at both ends (deep excavations and

large and heavily reinforced foundations) and in between the

abutments (heavy-duty reinforced floor). The future is with the

multifunctional self-reacting beds: quick, flexible, versatile

and above all value for money. According to Construx it is

the most economical way of producing prestressed concrete

elements.

Self-reacting beam casting beds



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Three different types of adjustable and modular double-sided shutters for prestressed beams

with an overall length of 5 x 36 m

Prebeton invested in three different types of adjustable girder

moulds, in order to cover all their requirements: rectangular

beams, inverse-T beams, I-girders, IV-roof girders and T-roof

girders. All three types can easily be fitted onto the self-react-

ing casting beds, the 50 mm increment pattern of the beds

corresponds with the holes in the bottom of the moulds. Con-

strux also included an extra fixing system which consists of

foot plates with the same 50 mm increment pattern and a hor-

izontal connection to the moulds. This system can be used

when both sides of the mould are too close together and out

of reach from the 50 mm hole pattern of the bed. In length,

the moulds are all three conceived as modular systems, they

have 6 m, 4 m, 3 m, 2 m and 1 m long parts. This avoids mould

parts sticking out too far beyond the prestressed concrete el-

ements, which would cause a large gap in between two ele-

ments. This would result in a waste of strand and a low bed

efficiency.

The rectangular and Inverse-T beams are manufactured in the

same adjustable and modular moulds. These moulds may be

used for all sorts of prestressed elements with a height of up

to 1,500 mm. Construx supplied one complete 36 m long

double-sided mould. This 36 m long set consist of six double

sided moulds of 6 m. The mould is conceived as a rigid flat

panel system and consists of panels with three different

heights: 400 mm, 600 mm and 800 mm. These panels can be

used separate or on top of each other, thus avoiding finishing

the concrete surface too deep down. Both sides of the mould

are interconnected at the top of the panels with tie-rods and

fixed onto the self-reacting bed with bolts through the holes

in the base or by means of the extra foot plate fixing system.

The distance in between both sides of the mould can be ad-

justed in accordance with the 50 mm increment pattern of the

bed. The flexibility and modularity of this system, in height

and in length, allows for future extensions by purchasing more

and different sizes of panels.

To make inverse T-beams, the rectangular panels serve as a

bottom form on which small vertical posts are bolted. Special

510 mm high and 200 mm thick box-out panels can be fit

onto these posts, in order to form a 200 mm recess on both

sides of the girder. When using the 800 mm high rectangular

beam mould panels at the bottom, the girder height can be

up to 1,300 mm. Construx also supplied a complete 36 m

long double set of box-out panels and vertical posts.

The I- and IV-beam mould system for roof girders is suitable

to manufacture elements of up to 1,800 mm high. Construx

supplied two complete 36 m long double-sided moulds. Both

36 m long sets consist of two double sided moulds of 6 m,

two moulds of 4 m, two moulds of 3 m, four moulds of 2 m

and two moulds of 1 m. The complete mould set is conceived

as an open frame with a longitudinal rigid base and 2 m high




NPCA_P_Show_ad_CPI_Europe_2021.indd 1 4/3/20 10:25 AM

PREBeton Zrt.

3358 Erdőtelek

Hrsz. 0336/18

T +36 302175588

[email protected]

www.prebeton.hu

Construx

Hazebeekstraat 11

8531 Hulste, Belgium

T +32 56724793

[email protected]

www.construx.eu

FURTHER INFORMATION

vertical posts. Both sides of the mould are interconnected at

the top of these posts with tie-rods and fixed onto the self-re-

acting bed with bolts through the holes in the base. The dis-

tance in between both sides of the mould can be adjusted in

accordance with the 50 mm increment pattern of the bed, al-

though most of the I- and IV-beams are made with a 400 mm,

500 mm or 600 mm standard base width. The depth and the

angle of the chamfers creating the taper of the flange of the

I and IV shape are chosen by the customer. A cut to measure

plywood covers the gap in between top and bottom chamfers

and is held in place by means of horizontal supports. The

thickness of the flanges, top and bottom, is adjustable. This

flexibility allows for a wide range of girders, up to 1,800 mm

high. Even rectangular prestressed beams can be manufac-

tured with this mould system, by removing the adjustable

chamfers and using shorter horizontal supports.

The T-roof beams are made in a similar set of moulds as the

I- and IV-beam mould system, but their top flanges have a

different height and angle than the top flange of the I- and

IV-beams. Construx supplied two complete 36 m long dou-

ble-sided moulds. Both 36 m long sets consist of two double

sided moulds of 6 m, two moulds of 4 m, two moulds of 3 m,

four moulds of 2 m and two moulds of 1 m. The complete

mould has the same open frame concept as the I- and

IV-beam moulds, with a longitudinal rigid base and 2 m high

vertical posts.

Hydraulically operated precast concrete buckets Construx supplied five made-to-measure precast concrete

buckets, all of which are hydraulically operated. The buckets

are equipped with a complete powerpack, a battery and a

remote control. They also have a vibrator to facilitate the

discharging or the bucket. Prebeton purchased two buckets

of 1,5 m³ and three buckets of 2 m³

Shaping the future of concrete The Construx “one-stop-shop” approach also resulted in the

purchase of a large number of 250 kg PU-magnets, 1,000 kg

box-magnets with a steel side flange, 2,000 kg box-magnets

with side-bars, straight side-form brackets, corner side-form

brackets and steel open side-forms at different lengths and

heights. Construx complied with the short lead time and with

Prebeton’s requirement to obtain a multifunctional, flexible,

and versatile solution to manufacture their prestressed con-

crete elements. The outcome of achieving these objectives

was a very satisfied customer.

Construx is an engineering-driven manufacturing company

relying on the commitment, creativity and experience of its

employees. Their aim is to establish a partnership, rather than

to be a supplier, in providing turnkey solutions for precast and

on-site formwork issues. �

Self-reacting beam casting bed with adjustable beam mould Precast concrete buckets


complete and brand-new precast factory in hungary

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