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The commissioning of the works by BoleynMagic Wall Panel is an innovation for theKenyan construction industry, which is stillstrongly influenced by the tradition of con-structing with stone and mortar. With acapacity of 20,000 dwelling units in oneyear it intends to contribute to relieving thenational housing shortage. Kenya's need tocatch up in this area is clarified by a figurefrom the Ministry of Land, Housing andUrban Development: up to 200,000 hous-ing units are needed every year. Now aState construction programme is promotingalternative construction methods alongsidethe traditional methods, in order to remedythe deficit. Construction with precast con-crete elements is attractive because of itsmany advantages.

Also Jack Liu, the Managing Director ofBoleyn Magic Wall points out the potentialof precast concrete technology, because it

is not only construction time, which isreduced, but also the costs. "We can antici-pate a cost reduction of about 20%,"explains Liu. This makes it possible to meetthe increasing demand for cost-effective liv-ing space. In addition, according to Liu,precast concrete technology is also ameans of assuring the quality, which shouldprevent the frequent cases of building col-lapse caused by structural defects.

New plant for hollow core slab produc-tion from Echo Precast Engineering

The new plant for the manufacture of hol-low core slabs has been planned in collab-oration with Echo Precast Engineering andcomprises four production beds, each 1.2m wide and 102 m long. Both beds havebeen custom-built and their distinctive con-struction ensures the optimum quality of thehollow core slabs produced there.

The hollow core slabs themselves are pro-duced with the S-Liner T40 slipformer. Themachine has been supplied with six differ-ent tube and mould sets. This allows the pro-duction of hollow core slabs in four differentheights from 15 to 40 cm, two differentwidths (60 cm and 120 cm) and there is anoption of 6 or 11 cores. Thanks to the mod-ular construction of the slipformer, changingthe tube and mould sets is quick and easy. In order to support both the manufacture ofhollow core slabs and the production of pil-lars, the slipformer can be fitted with anadditional tube and mould set.

Once they have been cured, the concreteelements are lifted from the bed by a spe-cial hoisting unit and stored or loaded on toHGVs and then transported to the construc-tion site.

Kenya: Commissioning of the first modern precast concrete plant

Tecnocom, 33100 Udine, Italy

Recently a new precast concrete plant began operation in Kitengela in the south of the Kenyan capital, Nairobi. Boleyn Magic Wall PanelLimited, the operator of Kenya's first modern precast concrete plant installs precast concrete elements for residential, commercial and infra-structure construction. The company's goal is to establish construction in precast concrete in Kenya and to make a contribution to the solu-tion of the chronic housing shortage in this country in East Africa. Echo Precast Engineering and Tecnocom, both companies in the ProgressGroup, supplied and installed a plant for the production of hollow core slabs and other equipment for the manufacture of structural, pre-stressed and loosely reinforced precast concrete elements.

Using plant and mould systems from Echo Precast Engineering andTecnocom, Boleyn Magic Wall Panel is manufacturing hollow coreslabs, sandwich walls, columns, beams and other structural precastconcrete and special elements.

An S-Liner T40 slip former is used for the production of hollow core slabs. These can be manufactured in four different heights, twodifferent widths and with 6 or 11 cores. In addition, the slip formercan be converted to the production of pillars.

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Various mould systems, tilting tabletechnology and pallets from Tecnocom

In its capacity as a company specialising inspecial moulds, Tecnocom has installed atotal of ten mould systems for the manufac-ture of columns, various beams, plinths,staircases and New Jersey barriers forstreets. Furthermore, Tecnocom has sup-plied modern tilting table technology forthe production of sandwich walls. In addi-tion, just recently Boleyn Magic Wall hasordered another 20 pallets for the car-rousel system.

Six column moulds and one plinth mouldfor the construction of industrial hallsand multi-storey car parks

The six 18 metre long column moulds,which have been installed on the produc-tion line for the production of structural pre-cast concrete elements, are being used tomanufacture columns, plus their consoles. Ahydraulic system adjusts the width of thecolumns by up to 500 mm. The maximumheight of the elements is 1000 mm. The endproducts are used in the construction ofindustrial halls and multi-storey car parks. The plinths for the columns are manufac-tured using a specialised mould. At its base

A total of six moulds, each 18 m long, are used for the manufacture of columns for commercial construction.

A mould with a self-stressing system for preloaded stresses can be fitted with various lateralshutters and insets. This allows flexible production of various types of beams.

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RECKLI GMBHGEWERKENSTR. 9A44628 HERNEGERMANYTEL. +49 (0) 2323 | 1706-0FAX +49 (0) 2323 | 1706-50INFO@RECKLI.DE

www.reckli.com

this has a diameter of 2 m; it is 1.3 m high and tapers towards thetop. A multi-frequency vibration system ensures optimum curing ofthe concrete.

Flexible mould system for various types of pre-stressed beams

In order to keep the production of beams as flexible as possible,Boleyn is using a mould system with independent absorption of thepre-loaded stresses, which can be fitted with a variety of lateral shut-ters and insets. In this way space is saved and roof trusses, T-beams,L-beams, right-angled beams and I-beams can be manufactured.The overall length of the mould system is 60 m. It can be used inde-pendently of location and smoothly installed at other productionsites.

A staircase mould and a battery mould for New Jersey barrierscomplete the stationary production of precast concrete elements.

Versatile, efficient production

In close cooperation with Boleyn Magic Wall Panel, Echo PrecastEngine ering and Tecnocom have provided custom-made solutionsfor the Kenyan market, which allow production to be both versatileand efficient. "The cooperation with both companies was excellentat all times - and it still is," says the Managing Director, Jack Liu withsatisfaction, as he expresses his confidence in the perspectives forthe new construction method in Kenya. "I am convinced that themany advantages of precast concrete construction will convinceeven the remaining sceptics and that this technology will becomeestablished here as well." �

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FURTHER INFORMATION

Boleyn Magic Wall Panel Ltd.P.O. Box 18056 – 00500 2nd Floor Liberty Plaza, Mombasa RoadNairobi, KenyaT +254203591088

Echo Precast Engineering NVIndustrieterrein Centrum Zuid 15333530 Houthalen, BelgiumT +32 11 600800, F +32 11 522093info@echoprecast.com, www.echoprecast.com

TecnocomVia Antonio Zanussi 30533100 Udine, ItalyT +39 0432 621222, F +39 0432 621200info@tecnocom.com, www.tecnocom.com

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