The Spanish company Moldtech S.L., specialized in the design and manufacturing of equipment for the precast concrete industry, has completed for its client MIKS-CONSTRUCTION Ltd.—one of Bulgaria’s leading producers of precast concrete elements—the installation and commissioning of a new production line for TT slabs and structural columns at its ZSK STOMANOBETON plant in Sofia.
The project, which covers the design, manufacturing, assembly, and commissioning of all equipment, incorporates long-length moulds, high-capacity stressing heads, and integrated hydraulic systems, optimizing the manufacturing, stressing, and curing processes in industrial applications.
MIKS-CONSTRUCTION Ltd.: expanding production capacity
Based in Sofia (Bulgaria), MIKS-CONSTRUCTION Ltd. has an extensive track record in industrial construction and the production of precast concrete elements.
The company operates a modern plant located in the Kremikovtzi industrial area, equipped with advanced European technology for the manufacture of beams, columns, panels and roof slabs.
As part of its modernization plan, MIKS entrusted Moldtech with the development of a new production line that enables the company to increase its output of prestressed elements and strengthen its position as one of the leading precast manufacturers in Eastern Europe.
Supplied equipment
The supply provided by Moldtech comprised a complete set of equipment and auxiliary systems for the production of prestressed elements: a mould for TT slabs (50 m long), including 600-tonne stressing heads, two sets of magnetic formwork, a one-lane column mould (34 m long), as well as bottom plates, separators and associated hydraulic power units. All equipment was designed and manufactured at Moldtech’s facilities in Alcalá de Guadaíra (Seville, Spain), and subsequently transported, assembled and commissioned at the MIKS-CONSTRUCTION plant.
The new production line combines high-capacity equipment with precision hydraulic systems. The main technical characteristics of the supplied equipment are detailed below.
Mould for TT slabs, 600 T, L = 50 m: manufacture of high-capacity prestressed slabs
The mould for TT slabs of maximum stressing capacity – 600 T, L = 50 m has been designed for the production of prestressed concrete slabs with variable cross-sections, used either as a base for in-situ cast floors or as roof elements for industrial and commercial buildings.
The system consists of four modules that form a continuous line with a useful length of 50 meters, facilitating both transport and installation on site or at the precast plant.
The mould incorporates an active and a passive stressing heads, located at both ends of a central core. Together with the side panels and base plates, these elements define the final geometry of the pieces to be manufactured.
For its proper operation, Moldtech supplied two hydraulic power units:
one for opening and closing the side panels and for the vertical movement of the bottoms, and another for the hydraulic detensioning process of the strands.
During operation, the mould can be complemented by various auxiliary systems — a hydraulic detensioning unit, a heating system for concrete curing, stressing accessories compatible with the maximum capacity of 600 tonnes, and a hydraulic unit for synchronized movement of the side panels — all designed to optimise production and ensure the highest quality of the final product.
The TT slab mould features variable geometry, enabling rib heights to be adjusted from 400 mm to 800 mm and slab widths to be configured from 1.42 m to 2.49 m.
The mould incorporates hydraulically adjustable and interchangeable base plates, allowing quick and precise changes to the slab section according to project requirements.
In addition, the mould is preinstalled with a heating system comprising covers and pipes for the circulation of a thermal fluid, enabling accelerated curing of the concrete and reducing production cycle times.
The maximum stressing capacity of the mould reaches 600 tonnes, distributed among four detensioning cylinders located in the active head: two 200 tonnes cylinders in the lower mask and two 50 tonnes cylinders in the upper mask.
The self-reacting TT mould integrates both the stressing heads and the main structure, simplifying installation, dismantling and potential relocation to other production sites.
Hydraulic column mould L = 34 m: manufacture of long structural elements
The hydraulic column mould L = 34 m is designed for the production of reinforced concrete columns up to 34 meters in length, with adjustable cross-sections between 400 mm and 900 mm.
Its hydraulic system, composed of synchronized cylinders, allows safe and efficient operation for the opening, closing and lifting of the bottoms, thereby optimizing production times.
The equipment consists of two side panels (34 m each) and a base (800 mm wide), which, when assembled, define the final geometry of the column.
The mould allows for the installation of corbels on all four faces, offering great versatility in the configuration of structural elements.
It is fitted with anchoring plates for integrated vibrators, designed to improve concrete compaction and surface finish. Optionally, it can be equipped with a heating system using finned pipes for the circulation of hot water or steam, accelerating curing and improving thermal efficiency.
Its modular design allows for the expansion of production capacity through the assembly of several sections in series, separated by dividers or spacers, depending on the plant’s requirements.
Execution and commissioning
The project was managed entirely by Moldtech, covering all stages of the process: engineering design and manufacturing, transport and installation at the client´s plant, hydraulic and electrical connections, and calibration and functional testing.
Following commissioning, the line is now fully operational at the MIKS-CONSTRUCTION facility, producing TT slabs and columns for industrial and logistics projects.
The new equipment enables a reduction in production cycle times, an increase in manufacturing capacity, and dimensional accuracy in each element produced, ensuring safe and reliable operation.
This project strengthens technological cooperation between European manufacturers and confirms Moldtech S.L. as a specialized supplier of customized solutions for precast concrete plants.
The production line installed at MIKS-CONSTRUCTION Ltd. exemplifies how the integration of hydraulic systems, modularity of the moulds and high-capacity prestressing equipment contributes to the efficient and sustainable industrialization of the precast sector, while consolidating Moldtech’s presence in Eastern Europe.
