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Hollowcore production solutions
Our aim is simple: to provide our customers with the highest quality hollowcore slab at the best possible price.
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 highest quality hollowcore slab at the best 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.
Our approach is founded on over 40 years of technical know-how and precast manufacturing experience alignedwith 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.
The purchase of the intellectual property andmanufacturing rights of Dynacore Equipment Canada Limited, manufacturers of the cutting edge EM line of extruders since 2007, has allowed us to combine Spiroll and Dynacore hollowcore extrusion technology.
This will take the development of our hollowcore extruders to the next level and enable us to offer a more comprehensive package of precast machinery.
Spiroll specialise in tailoredproduction systems for the manufactureof prestressed hollowcore slabs
Our ApproachAp
prai
sal
In providing turnkey solutionsfor low cost hollowcoreproduction, we manage everyaspect of the developmentprocess for factory start-ups.
Supp
ort
Trai
ning
Desig
n
Analysis of costs and payback Project planning Machinery requirements Feasibility study
Extruder & saw operator training Safe systems of work Stressing training Software training
Hollowcore slab design Factory design & layout drawings Production capacity planning Casting bed drawings
Project management Quality control system Spares & maintenance Calibration
Com
miss
ioni
ng
Inst
alla
tion
Spec
ifica
tion
Prod
uctio
n Casting beds & abutments Installation of essential services Cranes/batching plant/mixer Preset machinery ready to go
Batching plant/mixer specification Bed heating system specification Prestress wire/strand requirements Concrete distribution/handling requirements
Concrete mix design Demonstration of complete production cycle Every depth of hollowcore slab manufactured Confirmation all systems operating
Staged delivery of production equipment Support for local manufacturing Support for local procurement
Case StudiesSpiroll hollowcore production plants are currently operating in over 20 countries throughout the world, some of our projects are featured here:
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.
1,689,934ft2 (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.
“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.”
Saudi Oger Ltd.
Saudi Arabia 8 x 492ft (150m) production beds One Year project management contract 1,689,934ft2 (157,000m2) of slabs for KAUST Operational within 6 months
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 6in (150m) through to 13in (330mm) 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.
The first major project to be undertaken jointly by CCL and Spiroll was a hollowcore factory in Abuja, Nigeria for ITB Nigeria Limited, to produce Spiroll slabs for the construction of a new International Convention Centre in the Nigerian capital.
The Abuja factory produces over 5,382ft2 (500m2) of high-quality hollowcore slabs per day on 4 x 394ft (120m) long casting beds, in 5 different depths from 6in (150m) - 14in (356mm).
Spiroll and CCL supplied both machinery and project management. Machinery included a universal extruder, a multi-angle saw and a bed cleaner which allows beds to be prepared in less than 15 minutes by only one operative.
“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.”
“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 importance of Spiroll machines is that they are easy to operate and maintain, with minimum manpower. The extruder provides a high quality hollow core slab with the absence of cracks or weak spots on it ”
Kon-Bet
Poland 5 x 295ft (90m) production beds Factory design Universal Spiroll extruder Full training package translated into Polish
ITB Nigeria Ltd.
Nigeria 4 x 394ft (120m) production beds Universal Spiroll extruder 5 different depths of hollowcore slabs 2,152,782ft2 (200,000m2) of slabs for Convention Centre
Benefi ts of Spiroll Hollowcore
Profi tableFew 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 6in (150mm)and 8in (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.
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 and 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.
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.
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
The Spiroll production system is an internationally proven, economicalmethod for the production of high quality prestressed hollowcore slabs.
Why use Spiroll?
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
ProductsAlongside turnkey solutions for low cost hollowcore production, we provide a wide range of supporting 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
Hollowcore Machinery Prestressing Equipment Site Safety Systems
ServicesWe also provide a comprehensive range of tailored services to support hollowcore production and prestressing of precast concrete:
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 fi xing manual
Double tees
Rib slabs
Columns
Beams
T-beams
Slab fl ooring
Hollowcore Production Support
Design and manufacturing support are available throughour consultancy and technical services department forthe following prestressed precast products:
Contact UsFind out more about the benefi ts 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
Tel: +44 (0)1332 365 131
Fax: +44 (0)1332 291 736
Email: [email protected]
Web: www.spiroll.co.uk
Spiroll Precast Services LtdUnit 2, Kingsway Industrial ParkDerbyDE22 3FPUnited Kingdom
Hollowcore production solutions
