Leap from traditional methods to prefabricated construction method
The principles of quality, sustainability and efficient construction are central to Gamuda‘s business. Consequently, the obvious next step for Malaysia‘s leading infrastructure and land developer was to invest in modern technology for the manufacture of precast concrete elements. In 2016 a new precast concrete plant began operation near Kuala Lumpur. By opening this plant the company made the leap from traditional building methods to construction in prefabricated concrete sections, a method with a promising future.
More than 2,000 residential units per year
Gamuda‘s aim was to acquire a turnkey plant to produce solid walls and slabs for their own needs. This should drastically reduce construction times and guarantee consistently high quality. They worked with EBAWE Anlagentechnik to implement a concept for a carrousel system, which can be used to produce up to 1,000,000 m2 of wall and ceiling elements per year.
Efficiency through automation
Integrated software solutions, intelligent machine control systems, logistics systems and robots ensure that the production process in the new plant runs at a highly automated level. This minimises sources of error and at the same time improves rates of production and quality. The shuttering and de-shuttering, for instance, has been entirely taken over by the Form Master shuttering and de-shuttering robot. The manufacture of made to measure mesh also follows the efficiency principle. Rebar mesh is produced by a M-System BlueMesh type mesh welding plant to individual specifications and then placed automatically on the pallet. This, together with the VGA lattice girder welding plant and the EBA S automatic stirrup bender, enables Gamuda to manufacture the required made to measure mesh completely autonomously and just in time. In the carrousel system the automatic concrete spreader ensures additional efficiency, since it spreads fresh concrete with precision and at a steady rate. After compaction, smoothing and curing the fished elements are removed and stored.
Individual precast concrete elements of the highest quality
A first project, the 20-storey Jade Hills residential complex has already been completed. With the new carrousel system Gamuda now has the capacity to produce prefabricated elements for all its many future projects totally in accordance with the company motto, „Quality Beyond Aesthetics.“