A line for the production of prestressed reinforced concrete beams

Steel moulds

Prefabricated reinforced concrete structures and prestressed concrete structures are the basis of modern building construction.
Prestressed concrete products, unlike the non-prestressed ones, have a whole range of advantages.
During the manufacturing process, high-tensile rebar or a steel tendon is tensioned, which causes prestressing (i.e. stressing before service load)—it stretches the rebar and contracts the concrete. It makes it possible to:

• increase crack resistance and life span of the structure;
• improve elastic properties of structures (concrete products resist compression and deflection well);
• use (up to 40–50 %) less steel and make the structure lighter;
• use structures for large spans rationally and efficiently;
• make the building safer, because the collision will be preceded by extreme deflection, etc.

M-Konstruktor manufactures sides for the production of prestressed reinforced concrete support beams. Together with rebar stressing abutments (you can also order those from us), they form a set for the production of prestressed reinforced concrete products.

The standard length of a set is 12.5 m. It is suitable for the production of a 12 m beam. If you need to manufacture several concrete products at once, you can assemble the sides into a single production line or a single structure. It will allow you to get longer products with a length of 24 or 36 m.

The section of a concrete product may vary in width due to the wide range of motion of the sides—up to 1 m (this value may be increased at your request). The height section of the beam may be changed by pouring less concrete in a mould or by application of a special insertion mounted on the stationary bed. The standard height section of the beam is 1,100 mm (the height may be changed according to the customer’s request).

At your request, we can manufacture sides in segments with a length of 1, 2, or 3 rm, which will enable you to quickly and easily readjust the mould to get a concrete product of a required section.

Moreover, the sided can be equipped with special insertions that make the section of a concrete beam narrower in specific places.

To reinforce the concrete, steel tendons are pulled from one side of the mould to the other one with the help of tensioning abutments. The tendons are tensioned with the help of a hydraulic jack. Then the concrete mixture is poured inside the mould. When the concrete gains the required strength, steel tendons are slowly released. In this case, the reaction force from the tension of the tendon/rebar is initially transferred to special abutments, and after pouring and consolidation of the concrete, the tensioning devices are released, and the rebar/tendons contract and transfer compressive strength to the concrete. After that, the finished concrete product is safely demoulded and sent to the warehouse.

The production of prestressed structures requires particular precision. For example, if you fill the ducts with cement mixture in the wrong way, this will lead to rebar corrosion and the reduction of the structure’s strength and durability.

Tensioning abutments
Today, the most popular way to tension steel tendons is the tensioning of each separate tendon with the help of hydraulic jacks; the reaction force from such tension is transferred to abutments, which M-Konstruktor also manufactures.

Standard kit length is 12.5 meters. It moulds the 12-meters pole. If it is necessary to fabricate several reinforced concrete products simultaneously, sides can be assembled into production line allowing or a uniform system capable to fabricate piles of 24 and 36 running meters.

The cross section of reinforced concrete product can vary in width due to a movement capabilities of the sides – up to 1 m (optionally, you can increase the stroke of the sides). The height adjustment is possible by limiting the volume of concrete mixture or using the special insert mounted on a stationary pan. Maximum standard height is 1100 mm (this dimension can be modified upon the request).

Sides can be manufactured in segments of 1, 2 or 3 running meters as an option. This allows fast and easy readjustment of equipment for various cross-section products fabrication.

Sides can be equipped with a special inserts for the pole cross-section reduction at desired points.

Depending on fabricated products the stops of different dimensions and other parameters capable to withstand the stresses from 150 to 1000 tons are available.

Numerous openings in the poles allows to tension cables within various layouts providing product versatility.

You can get the information on the costs and delivery time from our specialists by phone: +7 (81153) 6-10-05 or e-mail: info@m-konstruktor.ru.

Delivery is available throughout the territory of Russian Federation as well as in the European Union and Eurasian Union countries. Railroad, heavy trucks, and sea transport delivery is available.