Gamuda invests in new production line for prestressed concrete elements

Quality, sustainability and efficient construction are key principles of business for Gamuda. Therefore, it was quite obvious for one of the leading infrastructure and landscape designers in Malaysia to invest in modern technology for the production of precast concrete elements. In 2016, a new precast concrete plant located near Kuala Lumpur was commissioned by Ebawe and Progress Maschinen & Automation. Opening this plant enabled the company to make the final leap from traditional construction methods towards promising construction with precast concrete elements.

In the next step, Gamuda has now extended the plant, investing in a production line for prestressed concrete elements. The Belgian company, Echo Precast Engineering, supplied all machinery and equipment, with the Slipformer S-Liner being the core component of the new production line. The company is part of the Progress Group, a leading supplier of machinery offering comprehensive solutions for the precast concrete industry.


Equipment for a high level of automation

The concrete plant, put into operation in 2016 with a high level of automation, was designed by Prilhofer Consulting for an annual production output of one million square meters of solid walls and lattice girder floors. Gamuda decided in favor of Ebawe Anlagentechnik and Progress Maschinen & Automation, both companies of the Progress Group, as principal suppliers. Ebawe delivered the equipment for the pallet circulation system.

Progress was responsible for the welding machines for mesh and lattice girders as well as all other reinforcement and mesh processing machines. The expansion of the plant by the new production line for prestressed concrete elements was also planned by Prilhofer Consulting. The aim was a capacity of at least 1400 m² of prestressed concrete elements per day. In order to achieve this goal, Echo has installed four production beds being 150 m long and 2.40 m wide and an Echo Slipformer S-Liner.

Slipformer S-Liner for more flexibility

The Slipformer S-Liner of Echo Precast Engineering stands for versatile, flexible production. The machine cannot only be used for the production of prestressed precast concrete floors, but also for other products such as beams, lintels, foundation piles, gutters as well as prestressed precast concrete floors with insulation or incorporated heating/cooling systems. This versatility is possible by a modular machine structure. Height adjustments can be realized within a product series by quick and problem-free changing of the tube and mold set. Changing to a completely different product is now possible in an even faster way by replacing the product-related modules.

Due to the specific design of the Slipformer S-Liner and the use of earth-dry concrete, this machine is a cost-effective solution that is easy to use and easy to maintain. Each machine type is available for beds with a width of 1.2 m, 1.5 m or 2.4 m. As mentioned above, Gamuda has decided to use beds being 2.4 m wide.


Production of two slabs with different widths simultaneously

The Gamuda company opted for the Slipformer technology because of the high level of flexibility. The possibility to produce two slabs with different widths (0.8 and 1.20 m) simultaneously underlines the flexibility of the Slipformer S-Liner and demonstrates the latest development of Echo Precast Engineering. This enables Gamuda to offer prestressed concrete elements in a thickness of 70, 90 or 110 mm.


New run-off carriage

Echo delivered the full range of equipment, including new developments such as a run-off carriage with a loading capacity of 30 tons. In the factory, this run-off carriage is transporting precast concrete elements to the storage area or to the loading area. The concrete elements are stacked horizontally on the loading area of the rail car.

The production line is completed by additional machines: the trolley for the processing tools, lifting equipment, a semi-automated portal concrete distributor with concrete bucket and a multi-function trolley for the preparation of the beds. The trolley is equipped with special rotating brushes for cleaning the production beds, a system for inserting the wires and strands as well as a system for oiling the production beds.

Echo Precast Engineering has attended the entire process from planning the production site to the installation through to the implementation of the machines.

Menara Gamuda
D-16-01, Block D, PJ Trade Centre
No. 8, Jalan PJU 8/8A
Bandar Damansara Perdana
47820 Petaling Jaya
Selangor Darul Ehsan, Malaysia
Echo Precast Engineering NV
Industrieterrein Centrum Zuid 1533
3530 Houthalen, Belgien
T + 32 11 600800
F + 32 11 522093
Ebawe Anlagentechnik GmbH
Dübener Landstr. 58
04838 Eilenburg, Deutschland
T +49 3423 6650
F +49 3423 665200
Progress Maschinen & Automation AG
Julius-Durst-Str. 100, 39042 Brixen, Italien
T +39 0472 979100
F +39 0472 979200
Prilhofer Consulting GmbH & Co. KG
Münchener Str. 1
83395 Freilassing, Deutschland
T +49 8654 69080
F +49 8654 690840

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