Hollowcore production solutions

Our aim is simple: to provide our customers with the best quality hollowcore slab at the lowest possible price.

Our approach is founded on over 40 years of technical know-how and precast manufacturing experience aligned with low overhead costs, people on the ground supporting a global customer base and an internationally proven hollowcore production system, providing customers with a competitive advantage and a manageable and affordable solution.

Spiroll hollowcore production plants are currently operating in over 20 countries throughout the world.

We deliver total solutions for hollowcore factory start-ups, providing machinery and support that achieves a quick payback.

As well as supporting a low cost entry strategy, our solutions provide provision for growth enabling manufacturers to increase production capacity in line with demand. Our aim is simple: to provide our customers with the best quality hollowcore slab at the lowest possible price.

Spiroll also offer a complete range of prestressing equipment, accessories and related services. We have a National accredited prestressing training scheme and provide consultancy and advice to support new and existing precast projects.

Spiroll specialise in tailored production systems for the manufacture of prestressed hollowcore slabs

Our aim is simple: to provide our customers with the best quality hollowcore slab at the lowest possible price.

Our approach is founded on over 40 years of technical know-how and precast manufacturing experience aligned with low overhead costs, people on the ground supporting a global customer base and an internationally proven hollowcore production system, providing customers with a competitive advantage and a manageable and affordable solution.

Spiroll hollowcore production plants are currently operating in over 20 countries throughout the world.

We deliver total solutions for hollowcore factory start-ups, providing machinery and support that achieves a quick payback.

As well as supporting a low cost entry strategy, our solutions provide provision for growth enabling manufacturers to increase production capacity in line with demand. Our aim is simple: to provide our customers with the best quality hollowcore slab at the lowest possible price.

Spiroll also offer a complete range of prestressing equipment, accessories and related services. We have a National accredited prestressing training scheme and provide consultancy and advice to support new and existing precast projects.

Spiroll specialise in tailored production systems for the manufacture of prestressed hollowcore slabs

Hollowcore slab designFactory design & layout drawingsProduction capacity planningCasting bed drawings

Appr

aisa

l

Desi

gn

Prod

uctio

n

Analysis of costs and paybackProject planningMachinery requirementsFeasibility study

Batching plant/mixer specificationBed heating system specificationPrestress wire/strand requirementsConcrete distribution/handling requirements

UK manufacturing baseStaged delivery of production equipmentSupport for local manufacturingSupport for local procurement

Spec

ifica

tion

Com

mis

sion

ing

Supp

ort

Casting beds & abutmentsInstallation of essential servicesCranes/batching plant/mixerPreset machinery ready to go

Inst

alla

tion

Trai

ning Concrete mix design

Demonstration of complete production cycleEvery depth of hollowcore slab manufacturedConfirmation all systems operating

Extruder & saw operator trainingSafe systems of workStressing trainingSoftware training

Project managementQuality control systemSpares & maintenanceCalibration

In providing turnkey solutions for low cost hollowcore production, we manage every aspect of the development process for factory start-ups.

Our Approach

Hollowcore slab designFactory design & layout drawingsProduction capacity planningCasting bed drawings

Appr

aisa

l

Desi

gn

Prod

uctio

n

Analysis of costs and paybackProject planningMachinery requirementsFeasibility study

Batching plant/mixer specificationBed heating system specificationPrestress wire/strand requirementsConcrete distribution/handling requirements

UK manufacturing baseStaged delivery of production equipmentSupport for local manufacturingSupport for local procurement

Spec

ifica

tion

Com

mis

sion

ing

Supp

ort

Casting beds & abutmentsInstallation of essential servicesCranes/batching plant/mixerPreset machinery ready to go

Inst

alla

tion

Trai

ning Concrete mix design

Demonstration of complete production cycleEvery depth of hollowcore slab manufacturedConfirmation all systems operating

Extruder & saw operator trainingSafe systems of workStressing trainingSoftware training

Project managementQuality control systemSpares & maintenanceCalibration

In providing turnkey solutions for low cost hollowcore production, we manage every aspect of the development process for factory start-ups.

Our Approach

Saudi Oger commissioned Spiroll to establish a turnkey factory for the continuous production of prestressed hollowcore slabs. The factory was designed, built and fully operational within six months.

157,000m² of hollowcore was manufactured specifically for the construction of the new King Abdullah University of Science & Technology (KAUST) in Jeddah which opened in September 2009.

A separate project management contract was agreed which provided a full time project manager and two technicians on location for 12 months to provide training and technical advice. The project management contract also provided factory design, slab design, specification and procurement of local factory equipment, quality assurance documentation and operational training and support.

Spiroll provided a total package of equipment and support to transform Kon-Bet’s existing precast shed into a fully functional hollowcore production facility.

The package covered everything from factory design and costing through to drawings for the local manufacture of the casting beds and supply of all the production machinery and accessories together with one week’s commissioning and training.

The package also included our latest universal extruder which produces hollowcore slabs from 150mm through to 320mm deep.

Spiroll also provided after sales support by returning to Poland and helping Kon-Bet at its official opening launch by presenting on to 130 leading Polish architects and prospective customers.

Barbados has a vibrant and rapidly expanding tourist industry. Hollowcore is contributing to this growth and was first introduced onto the island in 2006.

Demand had exceeded supply and in March 2007 Spiroll won a contract to provide a full package of equipment and support to supply a new venture with Cementum Inc.

Within six months an old sugar plantation site had been transformed into an efficient compact hollowcore production unit. Production commenced immediately, supplying hollowcore slabs and wall panels for Cementum’s sister company, Rotherley Construction.

8 x 150 metre production beds One Year project management contract 157,000m² of slabs for KAUST Operational within 6 months

5 x 90 metre production beds Factory design Universal Spiroll extruder Full training package translated into Polish

2 x 80 metre production beds Hollowcore start-up with provision to grow 150mm slabs for luxury villas Extruder wall panel conversion kit

Kon-Bet Cementum Inc.

Saudi Arabia Poland Barbados

The Spiroll system is reliable and produces a high quality final product. Spiroll’s vast knowledge and practical experience was invaluable during the plant building process. As experts in the field of precast concrete, they have helped us to solve many technical and technological issues.

The Spiroll hollowcore system was a key factor in constructing KAUST in a very quick timescale. Spiroll’s continuous support and technical advice allowed us to both win the contract and maintain high levels of quality during production.

Spiroll prestressed and precast technology allows us to exceed the expectations of our clients for quality and value in today’s construction market. We find their technical support team to be knowledgeable and dependable, and consider them an asset to our operation.

Spiroll hollowcore production plants are currently operating in over 20 countries throughout the world, some of our projects are featured here:

Case Studies

Saudi Oger Ltd.

Saudi Oger commissioned Spiroll to establish a turnkey factory for the continuous production of prestressed hollowcore slabs. The factory was designed, built and fully operational within six months.

157,000m² of hollowcore was manufactured specifically for the construction of the new King Abdullah University of Science & Technology (KAUST) in Jeddah which opened in September 2009.

A separate project management contract was agreed which provided a full time project manager and two technicians on location for 12 months to provide training and technical advice. The project management contract also provided factory design, slab design, specification and procurement of local factory equipment, quality assurance documentation and operational training and support.

Spiroll provided a total package of equipment and support to transform Kon-Bet’s existing precast shed into a fully functional hollowcore production facility.

The package covered everything from factory design and costing through to drawings for the local manufacture of the casting beds and supply of all the production machinery and accessories together with one week’s commissioning and training.

The package also included our latest universal extruder which produces hollowcore slabs from 150mm through to 320mm deep.

Spiroll also provided after sales support by returning to Poland and helping Kon-Bet at its official opening launch by presenting on to 130 leading Polish architects and prospective customers.

Barbados has a vibrant and rapidly expanding tourist industry. Hollowcore is contributing to this growth and was first introduced onto the island in 2006.

Demand had exceeded supply and in March 2007 Spiroll won a contract to provide a full package of equipment and support to supply a new venture with Cementum Inc.

Within six months an old sugar plantation site had been transformed into an efficient compact hollowcore production unit. Production commenced immediately, supplying hollowcore slabs and wall panels for Cementum’s sister company, Rotherley Construction.

8 x 150 metre production beds One Year project management contract 157,000m² of slabs for KAUST Operational within 6 months

5 x 90 metre production beds Factory design Universal Spiroll extruder Full training package translated into Polish

2 x 80 metre production beds Hollowcore start-up with provision to grow 150mm slabs for luxury villas Extruder wall panel conversion kit

Kon-Bet Cementum Inc.

Saudi Arabia Poland Barbados

The Spiroll system is reliable and produces a high quality final product. Spiroll’s vast knowledge and practical experience was invaluable during the plant building process. As experts in the field of precast concrete, they have helped us to solve many technical and technological issues.

The Spiroll hollowcore system was a key factor in constructing KAUST in a very quick timescale. Spiroll’s continous support and technical advice allowed us to both win the contract and maintain high levels of quality during producution.

Spiroll prestressed and precast technology allows us to exceed the expectations of our clients for quality and value in today’s construction market. We find their technical support team to be knowledgeable and dependable, and consider them an asset to our operation.

Spiroll hollowcore production plants are currently operating in over 20 countries throughout the world, some of our projects are featured here:

Case Studies

Saudi Oger Ltd.

ProfitableFew building materials available today offer the economy, flexibility and reliability of precast prestressed concrete. The Spiroll hollowcore slab can be utilised in many applications that present numerous sales opportunities in local markets.

FlexibleAs well as a versatile flooring and roofing application Spiroll hollowcore slabs can also be utilised for wall panels. A wall panel conversion kit for the extruder allows it to be easily converted to make 150mm and 200mm deep tongue and groove slabs.

FastSpiroll hollowcore provides producers with full control over all the variables which affect the durability, strength and appearance of the slab. The high quality and excellent finishes of the slabs reduce site work to an absolute minimum.

EconomicalSpiroll hollowcore slabs are up to 30% lighter than an equivalent in-situ floor. Building foundations and supporting columns/beams can be significantly reduced. Longer spans and greater loads can also be utilised from the Spiroll slabs.

QualityThe Spiroll extrusion process produces the most consistent and best quality hollowcore slab. This provides the ultimate in structural design and flexibility being entirely compatible with steel, masonry, hollowcore, concrete block and precast concrete beam constructions.

Benefits of Spiroll Hollowcore

high quality surface finishes Long spans High load bearing Sound insulating Fire resistant

Quality soffit finishes Good camber control Soffits painted directly Good shear capacity Used for wall panels

DurableSpiroll hollowcore slabs provide long term performance in extremely harsh conditions that could destroy lesser materials. It is extremely resilient to deterioration from the weather and the denser the slab the higher the fire rating.

GreenSpiroll slabs are also the best slab to be used by the hugely successful heating & ventilation system TermoDeck®. The system uses thermal masses to store energy in the slabs and is far more cost effective than conventional air conditioning systems.

ProfitableFew building materials available today offer the economy, flexibility and reliability of precast prestressed concrete. The Spiroll hollowcore slab can be utilised in many applications that present numerous sales opportunities in local markets.

FlexibleAs well as a versatile flooring and roofing application Spiroll hollowcore slabs can also be utilised for wall panels. A wall panel conversion kit for the extruder allows it to be easily converted to make 150mm and 200mm deep tongue and groove slabs.

FastSpiroll hollowcore provides producers with full control over all the variables which affect the durability, strength and appearance of the slab. The high quality and excellent finishes of the slabs reduce site work to an absolute minimum.

EconomicalSpiroll hollowcore slabs are up to 30% lighter than an equivalent in-situ floor. Building foundations and supporting columns/beams can be significantly reduced. Longer spans and greater loads can also be utilised from the Spiroll slabs.

QualityThe Spiroll extrusion process produces the most consistent and best quality hollowcore slab. This provides the ultimate in structural design and flexibility being entirely compatible with steel, masonry, hollowcore, concrete block and precast concrete beam constructions.

Benefits of Spiroll Hollowcore

high quality surface finishes Long spans High load bearing Sound insulating Fire resistant

Quality soffit finishes Good camber control Soffits painted directly Good shear capacity Used for wall panels

DurableSpiroll hollowcore slabs provide long term performance in extremely harsh conditions that could destroy lesser materials. It is extremely resilient to deterioration from the weather and the denser the slab the higher the fire rating.

GreenSpiroll slabs are also the best slab to be used by the hugely successful heating & ventilation system TermoDeck®. The system uses thermal masses to store energy in the slabs and is far more cost effective than conventional air conditioning systems.

Product quality Less cement Double casting Low scrap rates Good bond retention

Optimum bed utilisation Easy maintenance Off the shelf spare parts Universal extruder UK based manufacturer

Why use Spiroll?

The Spiroll production system is an internationally proven, economical method for the production of high quality prestressed hollowcore slabs.

The system is founded on a range of machines that are reliable, easy to maintain and deliver a consistent quality product. Our skill is providing machinery and support for projects with a quick capital pay back.

The design of the Spiroll extruder in utilising high frequency vibration delivers low cost production in relation to raw materials, labour and maintenance and is well supported through an ongoing development program as well as complete training packages and off the shelf spare parts availability.

Product quality Less cement Double casting Low scrap rates Good bond retention

Optimum bed utilisation Easy maintenance Off the shelf spare parts Universal extruder UK based manufacturer

Why use Spiroll?

The Spiroll production system is an internationally proven, economical method for the production of high quality prestressed hollowcore slabs.

The system is founded on a range of machines that are reliable, easy to maintain and deliver a consistent quality product. Our skill is providing machinery and support for projects with a quick capital pay back.

The design of the Spiroll extruder in utilising high frequency vibration delivers low cost production in relation to raw materials, labour and maintenance and is well supported through an ongoing development program as well as complete training packages and off the shelf spare parts availability.

Products

Hollowcore Design/Production Software

Universal Extruder

Saws

Bed Cleaners

Casting Beds & Heating Systems

Stressing Abutments

Hydraulic Detensioning Systems

Concrete Distribution Skips

Factory Lifting Clamps

Slab Insulation Covers

Wire/Strand Dispensers

Stressing Pumps

Stressing Jacks

Multi-stressing Systems

Stressing Grips

Stressing Cleaning Accessories

Rapidcut

Calibration Units

Strand Pushers

SlabLock Fixing Clamps

Fall Arrest Clamps

Edge Protection

Spare parts

Commissioning, maintenance, servicing, reconditioning

Prestressing training

Prestressing safe systems of work and risk assessments

Prestressing grip cleaning & inspection service

Prestressing equipment maintenance, servicing, calibrations

Management consultancy contracts

Hollowcore factory design

Hollowcore slab technical data

Wall panel information

Quality control manual

Site fixing manual

ServicesAlongside turnkey solutions for low cost hollowcore production, we provide a wide range of supporting products:

Site Safety SystemsHollowcore Machinery Prestressing Equipment Hollowcore Production Support

Double tees

Rib slabs

Columns

Beams

T-beams

Slab flooring

We also provide a comprehensive range of tailored services to support hollowcore production and prestressing of precast concrete:

Design and manufacturing support are available through our consultancy and technical services department for the following prestressed precast products:

Products

Hollowcore Design/Production Software

Universal Extruder

Saws

Bed Cleaners

Casting Beds & Heating Systems

Stressing Abutments

Hydraulic Detensioning Systems

Concrete Distribution Skips

Factory Lifting Clamps

Slab Insulation Covers

Wire/Strand Dispensers

Stressing Pumps

Stressing Jacks

Multi-stressing Systems

Stressing Grips

Stressing Cleaning Accessories

Rapidcut

Calibration Units

Strand Pushers

SlabLock Fixing Clamps

Fall Arrest Clamps

Edge Protection

Spare parts

Commissioning, maintenance, servicing, reconditioning

Prestressing training

Prestressing safe systems of work and risk assessments

Prestressing grip cleaning & inspection service

Prestressing equipment maintenance, servicing, calibrations

Management consultancy contracts

Hollowcore factory design

Hollowcore slab technical data

Wall panel information

Quality control manual

Site fixing manual

ServicesAlongside turnkey solutions for low cost hollowcore production, we provide a wide range of supporting products:

Site Safety SystemsHollowcore Machinery Prestressing Equipment Hollowcore Production Support

Double tees

Rib slabs

Columns

Beams

T-beams

Slab flooring

We also provide a comprehensive range of tailored services to support hollowcore production and prestressing of precast concrete:

Design and manufacturing support are available through our consultancy and technical services department for the following prestressed precast products:

Find out more about the benefits of Spiroll’s low cost hollowcore production systems – we can provide:

Detailed cost analysis for all aspects of production A payback model comparing the costs to your proposed output and selling prices

Contact us

Tel: +44 (0)1332 365 131

Fax: +44 (0)1332 291 736

Email: enquiries@spiroll.co.uk

Web: www.spiroll.co.uk

Spiroll Precast Services Ltd Unit 2, Kingsway Industrial Park Derby DE22 3FP United Kingdom

Hollowcore production solutions

Find out more about the benefits of Spiroll’s low cost hollowcore production systems – we can provide:

Detailed cost analysis for all aspects of production A payback model comparing the costs to your proposed output and selling prices

Contact us

Tel: +44 (0)1332 365 131

Fax: +44 (0)1332 291 736

Email: enquiries@spiroll.co.uk

Web: www.spiroll.co.uk

Spiroll Precast Services Ltd Unit 2, Kingsway Industrial Park Derby DE22 3FP United Kingdom

Hollowcore production solutions

Tel: +44 (0)1332 365 131 Fax: +44 (0)1332 291 736

Email: enquiries@spiroll.co.uk Web: www.spiroll.co.uk