Producer of pre-stressed concrete elements, G&J Industries, a family-owned company based in Belgium, has decided to boost its production capacity of its 60 cm wide hollow core slabs using a Extruder X-Liner® acquired from Echo Precast Engineering - a PROGRESS GROUP company. With this new machine on their 1.2m wide production beds, it is now possible to produce two slabs at the same time to meet the popular demand for the 60 cm wide slabs.

G&J specializes in hollow core slabs, solid floors, T-beams, stakes, and full and core lintels. Hollow core slabs comprise 50% of its production, which are sold throughout Belgium.

G&J Industries boosts production of hollow slabs with Extruder X-LinerProduction bed of 1,2 m, where two hollow core slabs of 60 cm width are being produced at the same time by an Extruder X-Liner®

Automated and efficient production of hollow core slabs
The innovative company was the first in Belgium to have its prefabricated elements certified with the CE and the BENOR marks, which bear testimony to the company’s constant drive for quality.

Almost 90% of the products are produced on-demand, and only 10% are in stock. In the process of producing hollow core slabs, concrete is pressed by screws on the production bed, compacted, and then cured on the production line. As regards automation, the company uses proven technology.

Though G&J normally produced the slabs using Slipformers, but now, with the Extruder X-Liner® it has increased production of the 60 cm wide slabs. This high-performance machine has been specifically designed to meet the needs in the residential and commercial sectors that require widths of 0.6 m in addition to the standard 1.2 m, 1.5 m and 2.4 m. These slabs can also be used in industrial constructions, in schools, etc.

G&J Industries boosts production of hollow slabs with Extruder X-LinerThe highly automated production machine Extruder X-Liner® FC with “shark screws” guarantee supreme compaction

The Extruder X-Liner®
Extruder X-Liner® FC (Flow Compaction) is designed to produce hollow core slabs through automated processes which are easy to manage by the operator. The Extruder X-Liner® installed at G&J Industries works on 1,2 m wide beds and produces two 60 cm wide hollow core slabs with heights of 160 mm and 180 mm in thickness. The versatile machine is also capable of producing hollow core slabs with a width of up to 1.2 m, simply by replacing a few components.

The X-Liner® modules can produce 160- and 180-mm heights to make 2 slabs of 60 cm (with 4 cores) simultaneously. Their unique combination screws and a center mold piece to split the slabs guarantees excellent compaction and quality on the 60 cm wide slabs.

G&J ordered a X-Liner® with a versatile nozzle unit which can also produce 9 core slabs of 160 x 1200 mm and 180 x 1200 mm.

G&J Industries boosts production of hollow slabs with Extruder X-Liner60 cm wide hollow core slabs, which are used a lot in the construction industry in Belgium

Shark screws for excellent performance
The maintenance-friendly X-Liner® with a high degree of flexibility can be individually adjusted to produce different slab heights in a short time. Also, the ratio between load and span can be adjusted by changing the concrete strength parameters and the reinforcement plan to suit specific applications. As a result, the production time, wear, and tear are reduced, and the whole process is easier to plan and handle, in addition to the time saved.

With its ‘shark screws’, specifically designed for this machine, it is possible to minimize the back rotation of the material inside the machine, so less power is needed for the compaction.

The X-Liner® is equipped with an integrated software ‘stabos’ from Progress Software Development (a company of Progress Group), which stores the production data locally and can then be integrated into the web client. The machine also includes a wireless connection for remote control from anywhere.

G&J Industries boosts production of hollow slabs with Extruder X-LinerThe Extruder X-Liner® only needs one machine operator to handle the concrete supply

Commented Gerard Oben, owner of the company, on the new acquisition, “The quality of the hollow core slabs is really good and is of the same quality as provided by a Slipformer, but with an additional nice finish. The machine is fast, and we like that it does not make noise and that it can self-drive. So, we need only one person to bring the concrete to the casting machine. Most importantly, the rate of production has increased significantly and with better compaction and a longer wear life of the slabs.”
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