Engineering Solutions for More Efficient Precast Production

The growing need for industrialized, efficient, and sustainable construction solutions has driven significant evolution in precast concrete production worldwide. With over 20 years of experience in the design and manufacture of precast equipment, Moldtech has developed custom solutions adapted to the technical and regulatory requirements of more than 70 countries. This article presents six recent case studies in various international markets where the company has implemented complete production lines or specialized equipment, resulting in improved productivity, geometric precision, and structural quality of the precast elements.

Egypt: Prestressed Bridge Girder Production for the Alexandria Metro

The new Alexandria Metro project includes a 21.7 km network with 20 stations and multiple elevated structures. For this context, Moldtech supplied a complete production plant for prestressed box-type girders, optimized for viaducts and overpasses.

The system featured two self-reacting production lines, designed to support stressing and destressing operations up to 1,900 tons. These lines include centralized vibration controlled remotely, improving concrete compaction and energy efficiency. The system also includes collapsible cores to enable smooth demolding without damaging the internal geometry of the girders, along with handling accessories to ensure safe movement of large-format elements.

The modular design of the molds and their automated operation allow for high production rates with reduced manpower, which is particularly advantageous in urban environments with logistical constraints. This solution has significantly accelerated construction timelines through precise and traceable off-site production.

United Kingdom: Hydraulic Mold for Bridge Piers for the HS2 Project

As part of the High Speed Two (HS2) railway projects – currently the largest infrastructure initiative in the United Kingdom – Moldtech supplied a custom hydraulic mold for producing large bridge piers with architectural finishes.

The system includes a fixed base and hydraulically synchronized side openings, allowing concrete casting to be carried out with the mold rotated 90° from the standard vertical position. This configuration facilitates the placement of steel reinforcement and improves control during the pouring of complex geometries. A custom-made device was also supplied to assist in steel placement and alignment.

One of the project’s major technical challenges was achieving tight dimensional tolerances and high-quality surface finishes on the visible faces of the piers. The adaptable closing system and high-grade materials used in the mold ensured the required aesthetic and structural standards were met, while maintaining a consistent and safe production pace.

Germany: 52.5-m Mold for TT Slab with Adjustable Height

In Germany, Moldtech was selected to design and manufacture a 52.5-meter-long mold for the production of prestressed TT slabs, intended for use in large logistics facilities and parking structures. The project required a flexible production system capable of adjusting slab sections to meet varying client specifications.

The mold features a hydraulically adjustable core for variable rib height, enabling the production of different slab geometries without the need for mechanical changeovers. It also incorporates next-generation electric vibration, controlled digitally to fine-tune frequency and amplitude depending on the concrete mix.

An integrated thermal curing system supports early strength development, allowing for shorter production cycles without compromising quality. The synchronized hydraulic tensioning unit (600 t total capacity) ensures uniform stress distribution throughout the length of the mold, in full compliance with German structural and environmental standards.

Uruguay: 60-m Tilting Table for Large-Scale Panel Production

Moldtech delivered a 60 x 4 meters hydraulic tilting table to a precast plant in Montevideo for the production of non-prestressed concrete panels up to 4 meters high. This installation is part of a national program to support mass housing and public infrastructure.

The table features integrated pneumatic vibration and internal heating to improve concrete compaction and reduce curing time. A laser projection system is used for geometry layout, and a longitudinal guide rail is adjustable to accommodate different formwork configurations.

The use of industrial magnets and phenolic formwork enables quick table reconfiguration between cycles, while the modular 7-section design allows for easy maintenance and potential relocation. This solution has helped the plant improve dimensional accuracy and increase output capacity without significantly expanding its workforce.

France: 3D Mold for Concrete Transformer Substation Production

In France, Moldtech supplied a complete production line for precast concrete transformer substations, designed for use in electrical distribution infrastructure. The system includes five large-format 3D molds (3.6 x 3.1 x 2.4 m), ten fixed assembly tables, and a carousel system that streamlines internal plant logistics.

The concrete substations are casted as monolithic peace in a single pouring operation ensuring structural integrity and consistent surface finish. The design includes quick-release systems and access points for inspection and cleaning, as well as safety platforms and security elements for operators.

The use of a rotating carousel has significantly reduced preparation and assembly times, providing better process traceability and overall productivity. The system is suitable for both standardized series and custom designs, increasing the commercial flexibility of the plant.

Technical Conclusion

The projects presented here reflect Moldtech’s approach as a global supplier of tailored engineering solutions for the precast concrete industry. Through custom design, in-house manufacturing, and field support, the company has addressed regulatory, geometric, and logistical challenges across diverse construction environments.

For the European market—and especially in France—this international experience represents a strong guarantee of technical reliability and added value. Collaboration with Moldtech enables precast producers to optimize resources, raise technical standards, and move toward a construction model that is more precise, rational, and ready for the future.