Moldtech has developed an automated circulation line for the internal transport, positioning and transfer of precast concrete bathroom pods at an industrialised construction plant in Cuenca, Spain.
The solution coordinates the movement of the modules between different workstations and storage positions, integrating longitudinal travel, transverse transfer, lifting, positioning, occupancy detection and centralised control.
The project forms part of the growing adoption of industrialised construction in residential developments, a model that progressively shifts more operations from the construction site to controlled production environments. In this context, the industrial manufacture of bathroom pods allows repetitive processes to be organised with greater precision, traceability and coordination throughout the different stages of production.
Industrialised construction for the residential sector
The growing adoption of precast and modular solutions in housing is transforming the way certain activities traditionally carried out directly on site are performed.
Precast bathroom pods are a particularly representative example of this evolution. Factory production makes it possible to bring together the different treatment, finishing, assembly and component installation operations within a single environment before the module is transported to the residential development.
This approach allows production to be structured around successive workstations, reduces reliance on operations carried out on site and improves the coordination of highly repetitive processes.
In residential developments comprising a large number of homes, this industrial organisation also provides greater planning stability and helps maintain consistent production standards across the different units.
An automated line designed for the internal transport of bathroom pods
To meet the plant’s production requirements, Moldtech has designed and manufactured an automated circulation line specifically conceived to transport precast concrete bathroom pods between different workstations and storage positions.
The installation is arranged around a central longitudinal track on which two independent transfer cars operate.
A total of 50 lateral cells are positioned on either side of this central axis, with 25 positions per side, to accommodate the modules during the different stages of the process.
The bathroom pods rest directly on the designated cells or on the transfer car itself, eliminating the need for intermediate pallets.
The line has been designed to handle modules of varying dimensions, ranging approximately from 1.9 × 2.1 metres to 2.4 × 4 metres, and weighing approximately between 1.6 and 3.7 tonnes.
Two independent transfer cars for longitudinal travel and transverse transfer
The modules are moved by two independent transfer cars that travel longitudinally along the shared central track.
Each car can be positioned opposite a selected lateral cell and, once correctly aligned and locked in place, perform a transverse movement to collect or deposit the bathroom pod.
The transverse transfer mechanism also incorporates a lifting system, allowing the module to be raised during collection and lowering operations before being placed in the corresponding position.
The sequence therefore combines four fundamental operations: longitudinal travel, positioning, transverse transfer and lifting.
This configuration allows the bathroom pods to be transported directly between different production or storage positions without requiring auxiliary handling equipment for each internal movement.
The line has 50 lateral cells distributed on both sides of the main route.
These positions can be used as work or storage areas within the production process, allowing different modules to remain at different stages of completion.
Automatic and manual operation from a centralised control system
The line can operate in either automatic or manual mode.
The main control panel and its HMI allow operators to manage both transfer cars, select origin and destination positions, monitor movements, configure parameters, administer users and view alarms.
A solution designed for finishing industrially manufactured bathroom pods
The purpose of the line is not to manufacture the structural module itself, but to facilitate its internal movement between the different positions used during the subsequent stages of the production process.
The bathroom pods can be moved between different cells for finishing, assembly, treatment or temporary storage operations, according to the plant’s production organisation.
This approach is particularly well suited to an industrial production environment in which different units may be at different stages simultaneously.
The ability to select the origin and destination of each module means that the production flow is not limited to a rigid linear sequence. This provides the flexibility required to manage intermediate situations, different processing times and storage requirements.
Precast bathroom pods for residential developments
The installation’s end application lies in one of the fastest-growing areas of industrialised construction: the manufacture of precast bathroom pods for residential buildings.
These modules make it possible to transfer a significant proportion of the work traditionally coordinated within each home to a factory environment.
Rather than concentrating every trade and operation directly on site, part of the process can be completed on each unit within a previously organised industrial environment.
Each bathroom pod moves through a series of workstations where the planned operations are progressively completed before dispatch.
This method makes it possible to apply the principles of industrial production: repeatability, process control, workload planning, traceability and verification of each unit.
In residential developments with a large number of homes and repetitive layouts, this model simplifies the organisation of the production process and reduces some of the complexity associated with subsequent coordination on site.
Industrialising not only the product, but also its movement within the factory
One of the project’s most significant features is that industrialisation is not limited to the final building element.
The way in which the module moves through the plant is also industrialised.
The line designed by Moldtech replaces isolated internal movements with a controlled system for transporting, positioning and transferring modules between cells.
The flow of the bathroom pods is thus integrated into the factory’s production system.
This development is particularly significant in industrialised construction: transferring processes from the construction site to the factory also requires systems capable of handling, storing, positioning and transporting elements in a manner compatible with organised production.
Moldtech as a technology partner for the industrialisation of precast production
Beyond the supply of a specific piece of equipment, this project demonstrates Moldtech’s ability to act as a technology partner in the development of bespoke production processes and installations.
The company’s expertise extends beyond the design and manufacture of moulds. Moldtech develops complete solutions for the precast and industrialised construction sectors, addressing requirements related to automation, internal transport, element handling, hydraulic systems, vibration, heating, prestressing, demoulding, storage and production-line organisation.
Every project begins with the customer’s specific production requirements, the geometry and weight of the elements, the required level of automation and the way the different processes must be integrated within the plant.
This approach enables Moldtech to develop everything from individual moulds to complete production lines, circulation systems, handling equipment and special solutions requiring dedicated engineering.
The ability to adapt equipment to each plant’s actual production process is particularly important in industrialisation projects, where standard solutions may not meet every production requirement.
Bespoke engineering for every precast production requirement
As a specialist manufacturer of moulds and equipment for the precast industry, Moldtech combines mechanical design, automation, hydraulics and production expertise to develop solutions tailored to different sectors and element types.
The company works on applications spanning residential and industrial buildings, civil engineering, infrastructure, modular construction and special precasting systems.
This multidisciplinary capability enables Moldtech to undertake projects ranging from tilting tables and panel moulds to prestressing lines, beam production systems, hydraulic solutions, turning equipment, transfer cars, automated lines and purpose-built automation systems.
In every case, the objective is to provide producers with a technically reliable, robust solution tailored to their industrial requirements.
Moldtech’s international experience
Designed and manufactured in Spain, this automated line adds to Moldtech’s extensive experience in developing industrial solutions for precast plants and industrialised construction processes.
With projects delivered in markets around the world, Moldtech maintains an approach based on bespoke engineering, equipment robustness, manufacturing precision and the integration of multiple technologies within a single solution.
The project developed in Cuenca demonstrates this capability: an installation designed specifically to organise the internal transport of heavy modules, coordinate different workstations and integrate the handling of precast bathroom pods into the industrial process.
As the sector moves towards higher levels of automation and control, Moldtech is positioning itself as a technology partner for manufacturers seeking to develop their plants, increase their industrial capacity or create new solutions for the precast and industrialised construction sectors.
