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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
Hulste (B)Genk (B)Roeselare (B)Boortmeerbeek (B)Veenendaal (NL)Bucharest (RO)
PRECAST CONCRETE ELEMENTS
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
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PRECAST CONCRETE ELEMENTS
CPI – Concrete Plant International – 5 | 2020 www.cpi-worldwide.com206
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
06b-Precast_180-211_en.qxp_Layout 1 03.09.20 10:19 Seite 206
PRECAST CONCRETE ELEMENTS
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
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PRECAST CONCRETE ELEMENTS
CPI – Concrete Plant International – 5 | 2020 www.cpi-worldwide.com208
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
06b-Precast_180-211_en.qxp_Layout 1 03.09.20 10:19 Seite 208
PRECAST CONCRETE ELEMENTS
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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
06b-Precast_180-211_en.qxp_Layout 1 03.09.20 10:19 Seite 209
PRECAST CONCRETE ELEMENTS
CPI – Concrete Plant International – 5 | 2020 www.cpi-worldwide.com210
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
www.prebeton.hu
Construx
Hazebeekstraat 11
8531 Hulste, Belgium
T +32 56724793
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
06b-Precast_180-211_en.qxp_Layout 1 03.09.20 10:19 Seite 210