South Korea Interconstech relies on Italian technology for the most efficient concrete distribution

Interconstech CO., Ltd. has been making a new history of construction technology through everlasting R&D. Ever since its founding, Interconstech Co., Ltd. (ICT) has forged ahead with a primary principle - the commitment to qualify leading the way. Unlimited endeavors to research and develop top-notch construction technology have, since the firm‘s inception, brought us the pride as a construction technology-oriented company, while serving the best satisfaction to customers.

Interconstech CO., Ltd. (ICT) is, in fact, the largest bridge company in Korea that has grown based on new technology development. In May 2017, in Goesan ICT launched the first factory for the production of a variety of precast products, using eco-friendly green technology: road segments arch, TBM segments with stationary molds and bridge beams.

Interconstech Co., Ltd. strives to be a company that raises a new vision and future to the construction industry through the development and trial of new construction methods and smart construction technologies. For this reason, in June 2018, it has officially announced the intention to enter into the TBM market and, in January 2019, the first TBM was purchased for the Bucheon Electric Power District. Due to the continued success, ICT installed a new universal carousel in the Goesan factory, in September 2020.

High-quality TBM segments manufactured by state-of-the-art production line

The ICT concrete segments, produced in the dedicated factory, are made with very strict quality control and advanced manufacturing technology applied to various shield TBM: either electric power, water and gas tunnel or road, railway and metro tunnels. In most cases, the segments are produced with steel and polypropylene fiber in order to increase the concrete workability, the resistance and the anti-fire performances.

The factory site has the possibility to store over 60.000 tunnel segments, this allows ICT to secure every TBM project, complying with different delivery times in multiple locations. The high production rate is guaranteed by Korea‘s first high-tech automated and universal carousel system construction. The automated production through the carousel system allows ICT a considerable cost reduction without affecting the high quality and customer’s satisfaction.

The first two projects are:

Bucheon (Jungdong ~ Gogang) power section construction Φ=2,8m, L=1.150m

Anseong~Pyeongtaek power district construction Φ=3,4m, L=3.757m

Universal carousel and most efficient concrete distribution

Adapting to the changing business environment during the planning and construction phases of the project is the key point for ICT: many factors have changed recently in the market and now there is an increasing demand for tunnel segment elements, railway sleepers and concrete poles.

„The changing world did not go unnoticed at ICT“, Mr. Jeon Seung-Wan ICT Factory Manager, said. He continues: „The business plans regarding the new precast production line were updated to correspond with the new market outlook.”

The challenge has been won when the automated carousel system had already been prepared also to cast railway sleepers, wall slabs and planks: in this way, ICT can manufacture concrete products for high-speed railroad (KTX), high-depth underground railroad (GTX), thanks to the approval of the Korean National Railroad Authority and the Korea Railroad Research Institute.

MCT Italy has been selected, after the successful supply of a full concrete distribution system installed in 2017, for the factory upgrade and to achieve the target of delivering the concrete to the new production hall.

The casting station of the new carousel system is over 250 meters away from the existing batching plant: the 270 m/minutes MCT Italy high speed flying bucket can fulfill the task to deliver the 1,77 m³ batch every 5 minutes. MCT Italy also applied a purpose studied flying bucket rail switch that automatically controls and organizes based on a dedicated list of priorities the two buckets running on the same loop.

The MCT concrete distributor is the outcome of several studies developed in a true partnership by ICT and MCT technical departments: due to the presence of the universal carousel, used for the production of multiple elements of various shapes, heights and dimensions, the casting machine is equipped with double gates and 360° rotation device, it can move up and down and from left to right.

The special request of the ICT technical team for automatic concrete pouring is easily helped by a dedicated screen: it shows the real-time quantity and it can be expressed in cubic meter or kilograms.

A user-friendly remote control completes the supply as the only casting operator can easily control several operations: call for the concrete, select the preferred mix design, adjust the plasticity and pour the concrete into the different molds for the production of various concrete elements.

MCT Italy shapes ICT dreams

“We strongly believe in the advantages of precast concrete construction because of the high quality, lower maintenance costs, and durability,” Mr. Kim Jong-Hyun explains.

Strong partner for long-term cooperation, MCT Italy, through the local support of Mr. Oh from Hanin corporation, has worked closely together with ICT throughout the project, offering consultation and advices regarding all aspects in the construction of the facility expansion. “When you are choosing a supplier for new precast equipment, it is essential to choose a strong, experienced firm with a specialized organization for continuous cooperation. After we got up to full speed with negotiations with MCT Italy, and our technical & consultant engineers supported us in comparing different suppliers, the contract was prepared in a very short time,” adds Kim Jong-Hyun.

“We got excellent feedback from MCT Italy regarding the business environment. They supported our specialized team and consultants, by networking with worldwide experts and development teams, strengthening our first steps in the construction industry with successful precast solutions for the South Korea market,” says Kim Jong-Hyun.

Best equipment to maximize the flexibility & speed of casting

Mr. Falchetti Gabriele, MCT Italy‘s South Korea Sales Director, says: “In order to achieve and work out the smartest solutions in the precast technology, production automation and services, it is crucial to monitor business conditions and to consult customers’ needs proactively. Our goal is to enable ICT to maintain high performances levels and to optimize the production rates.”

Mr. Kim Jong-Hyun points out: “ICT is supposed to produce concrete with maximum strength of 1,100 Mpa in the factory, we believe that MCT‘s flying bucket and casting machines are the best equipment to transport mixed concrete, assuring a speed of 4,5 meter per second and absolutely flexible cast for any type of elements.”

He continues: “MCT Italy is the one-stop supplier in the industry and they are able to match any need in precast concrete building construction with an upgradable production concept. Through the numerous meetings and modifications, we have applied the optimal design and system, and through this process, we have equipped the facility to produce products in the factory with the minimum number of people.”

Long-lasting lifetime partnership

MCT Italy‘s South Korea Sales Director Falchetti Gabriele says that the precast plant MCT has delivered in Goesan City is the first of its kind in South Korea. During the past years, South Korea has gone through changes that have had a boosting effect on the construction industry as the new leaders tackle the nation’s problems. “In this part of the world, there is an increasing demand for special precast elements utilizing the latest general of special concrete. Precast technology can offer an excellent solution for this. At MCT Italy, we help our customers adapting to the changing environment and to new business opportunities throughout the project. ICT’s project is an outstanding example of this approach,” Falchetti explains.

A precast plant is a long-term investment so there has to be room for flexibility, even in the unknown future. “We want to offer our customers all of our 53 years of experience & skills, professional networks, and the most flexible service available in the industry,” Mr. Oh from the MCT local team adds. These include services that enable customers to renew and maintain their skills, tools, and know-how during the production line’s lifetime.

Mr. Kim Jong-Hyun concludes: “By maintaining a profound respect for our past, and by reaffirming our commitment to quality thanks to MCT Italy in this new project, we are certain that our clients and our firm will enjoy a future that is even more exciting, successful and inspiring than our past.”