How to manufacture beams and hollow core slabs with Tensyland

How to manufacture beams and hollow core slabs with Tensyland

Tensyland technology is a process consisting of a set of machines and auxiliary equipment whose function is to manufacture pre-stressed concrete beams and hollow core slabs for their use in the construction of all types of buildings, such as housing, stadiums, car parks, auditoriums, schools, theatres, hospitals, etc.

Tensyland has been leader in the pre-stressed market for over 50 years, with a presence in over 50 countries. Its great versatility, robustness, low maintenance and easy handling the key element of the success of this technology for manufacturing beams and hollow core slabs and other pre-stressed products.

Also, as a result of the continuous research and investment in R&D&I, Prensoland has been incorporating different technological innovations, providing new solutions to the pre-stressed market.

Basically, the Tensyland facility comprises six manufacturing stages ranging from the preparation of the raw material (concrete) through to the storage of the fully finished product. In such a way that, at the same plant, our teams implement the different phases Producing the mixture, cleaning the beds, extending the cables, moulding the beams or slabs, cutting and extracting the product.


As we mentioned in a previous post, the function of the concrete batching plant is the dispensing and preparation of the concrete in order to supply it to the Tensyland Moulding machine.


The process of cleaning and drying the beds needs to be performed to ensure that the production beds are left completely dry and clean in order to start the manufacturing cycle. This process leaves the bed completely smooth and free of residues, thereby ensuring a perfect finish at the bottom of the product.


The wires are pulled using the Wire-pulling machines that are available in various versions. This machine extends the multiple steel wires or strands along the bed. These are then tensioned using the Hydraulic Tensioner, thereby leaving them suitably tense before moulding the items.

In order to optimise processes and times, Prensoland uses a Multipurpose trolley: an apparatus that performs the bed-cleaning and wire-laying operations at the same time. This machine can also spray on the concrete releasing agent in the same process.


The moulding process meanwhile is the centrepiece of the facility, referring to the system that manufactures all kinds of profiles and measurements on special beds designed for this function. The function of the Tensyland moulding machine is to manufacture beams and slabs in accordance with the mould chosen. Due to its versatility, it can manufacture all kinds of pre-stressed beams and slabs, with a simple change of mould in just 5 minutes, reaching a maximum possible height of 630 mm, although profiles are exclusively standardised to 500 mm.

In addition, the latest technological advance developed by Prensoland in the process of continuous pre-stressed concrete moulding is the manufacturing of hollow-core slabs with toothed sides.
The machine incorporates a programmable automaton in the control panel. Using a pulse generator and the corresponding programming, the moulding can be given certain characteristics that are indispensable for use in the construction of buildings in an area prone to earthquakes:

– A system of toothed sides for hollow-core slabs that gives extra friction to the joint, thereby adapting to Standards EN1992-1-1 and EN1168.
– A top marking system (carantage) for beams, which marks the top of the product in order to ensure a greater adhesion between these and the concrete poured over them as a compression layer.
– A system of visible wires at the length required and without degradation of the concrete.
– The stirrup inserting system, which inserts connecting stirrups at the top of the beams simultaneously.

As a result, the benefit provided by the toothed sides that is activated by a switch on the control panel is expressed dually:
(a) for a particular side of hollow-core slab, the teeth produce additional friction on the longitudinal joint,
(b) for a particular friction, the thickness of the compression layer can be reduced, with the consequent saving of concrete and therefore of the weight of the building.


Next, and once the moulding process is complete, the product remains on the bed while it sets. Sawing is then performed, and depending on the model of saw, it can be done in different ways: straight or at an angle. The saws are equipped with automatic devices and safety sensors that give the machine accuracy and complete autonomy, thereby helping to reduce the cost of labour.


Lastly, and once the product has been sawn, there only remains to extract it from the beds. This operation can be done using clamps, manipulated using a gantry crane or with the Stacker/Lifter Trolley. The extracted product is stored in the stocking area until it is transported to the works site.

Tensyland is a range of machinery for the system for manufacturing pre-stressed concrete that is adjusted to the needs of customers according to their objectives and the products to be manufactured.

Custom projects where we offer different technical solutions and complementary equipment for the aforementioned, such as:

The Printer/Plotter – for marking beams and slabs.
The Stirrup inserting system – for inserting connecting stirrups at the top of the beams.
The Top concrete layer – used to achieve different surface textures or finishes.
The Screeding machine – provides a perfect finish on the sides and tops of the beams.
A Special Features Machine (fresh concrete vacuum pump) – ideal for customers who produce reinforced beams.
Other additional equipment.

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