HOLLOWCORE

SOLUTIONS

SPECIALISTS IN HOLLOWCORE PRODUCTION SYSTEMS

www.spiroll.co.uk
02/03
Our aim is simple:
to provide each and
every customer with
solutions tailored to
match their exact
requirements.

www.spiroll.co.uk
ABOUT SPIROLL

Spiroll specialise in tailored production “The purchase of the intellectual

systems for the manufacture of property and manufacturing rights
prestressed hollowcore slabs. of Dynacore Equipment Canada Limited
has allowed us to combine Spiroll
We deliver solutions for both hollowcore start-ups
and existing manufacturers, providing machinery and Dynacore technology. Since 1962,
and support that achieves a quick payback. Spiroll have been at the forefront of
Our solutions support a low-cost entry strategy and hollowcore slab production machinery.
provision for growth in developing regions. In more The new Vortex extruder is the
mature markets we can provide competitive advantages
that maximise efficiency and minimise running costs.
culmination of over 50 years
Our aim is simple: to provide each and every customer of manufacturing experience,
with solutions tailored to match their exact requirements and ushers in a new generation of
Spiroll also offer a complete range of prestressing hollowcore extruder.”
equipment, accessories and related services. We have a
nationally accredited prestressing training scheme, and
provide consultancy to support new and existing projects.
Our approach is founded on over 50 years of technical
know-how and precast manufacturing experience.
We have people on the ground supporting a global
customer base, and an internationally proven
hollowcore production system.
Spiroll hollowcore production plants are currently
operating in over 20 countries throughout the world.

Hollowcore Solutions
04/05
OUR APPROACH

Our turnkey solutions cover factory start-ups

of all sizes - from smaller site based and temporary
projects, to comprehensive precast factories.

www.spiroll.co.uk
1. APPRAISAL 2. DESIGN
• Machinery requirements • Hollowcore slab design
• Project Planning • Factory layout
• Feasibility Study • Civil works

4. PRODUCTION 3. SPECIFICATION
• Staged delivery • Batching plant/mixer
• Local manufacturing support • Curing system
• Local procurement support • Concrete distribution/handling

5. INSTALLATION 6. COMMISSIONING
• Abutment civil work • Concrete mix design
• Casting beds • Complete production cycle
• Plant and services • Product quality

8. SUPPORT 7. TRAINING
• Project management • Machine operation
• Quality control • Prestressing
• Maintenance and spares • Safe systems of work

Hollowcore Solutions
06/07
CASE STUDIES

Spiroll hollowcore production plants are

currently operating in over 20 countries
throughout the world.

Botswana Innovation Hub

BOTSWANA

• 2 x 90m (295ft) production beds

• 40,000m2 (430,556ft2) of slabs “Spiroll slabs are a proven means of
• 250/300/340mm (10/12/13in) depths implementing the TermoDeck system
• Local manufacturing support in a building. The Spiroll production
The TermoDeck construction system, pioneered using
system, in conjunction with engineering
Spiroll hollowcore slabs, was used at Botswana’s first support, has ensured continuous and
science and technology park, the Botswana Innovation on time delivery of slabs for the project.”
Hub. TermoDeck uses the voids in the slabs instead
of steel ducts, to exchange air from the supply to the
building’s interior. This can produce savings in energy
consumption of between 20 – 50% and a reduction in
peak cooling loads of 70 – 90%.
Spiroll specified, designed and manufactured a
production system to supply 40,000m2 (430,556ft2)
of hollowcore slabs at depths of 250mm (10in), 300mm
(12in) and 340mm (13in) with a non-standard width of
1250mm (49in), from an outdoor, site-based factory.
The package of machinery included a universal extruder
with cassettes for the 25cm (10in) and 30cm (12in)
slabs and a special modification kit to manufacture the
34cm (13in) slabs. Spiroll also supplied a crosscut saw,
complete with an adaptation to allow simple angle cuts,
prestressing equipment and SlabLock lifting clamps
for bot factory handling and site fixing. The steel casting
beds were manufactured locally with design support
and a drawing package provided from the UK. Support
with commissioning and training was provided by Spiroll
engineers throughout the duration of the project.

www.spiroll.co.uk
 SKC Beton
KAZAKHSTAN

• 3 x 100m (328ft) casting beds

• Provision to expand to 5 beds “Since the first meeting Spiroll
• Mould and tables for other precast elements and Vikon were the clear choice to
• 50,000m2 (538,195ft2) of precast housing supply the machinery for this project.
SKC Beton, the largest supplier of cement and building
Delivery expectations were met and
materials in the Akmola region of Kazakhstan, the machines were making a high
commissioned Spiroll to supply a complete package of quality product from day one.”
equipment for prestressed hollowcore slab production
in one of the region’s first precast factories dedicated
to producing elements for housing construction.
The contract included a universal extruder, a crosscut
saw, bed cleaner and prestressing equipment. Three
100-metre (328ft) long casting beds were also installed
along with extra abutment pockets to allow for the
addition of two further beds in the future.
The first stage of the project involved the construction
of a 2-bay plant, each bay 144 metres (427ft) long and
24 metres (78ft) wide. At full capacity the plant
will produce 50,000m2 (538,195ft2) of housing per year.
As well as the hollowcore machinery, the factory has
a brand new batching plant, tilting table and a universal
casting bed for the production of reinforced concrete
structures.

ITB Nigeria Ltd.

NIGERIA

• 4 x 120m (394ft) production beds

• Universal Spiroll extruder “The importance of Spiroll machines
• 5 different depths of hollowcore slabs is that they are easy to operate and
• 200,000m2 (2,152,782ft2) of slabs for Convention Centre maintain, with minimum manpower.
The first major project to be undertaken jointly by
The extruder provides a high-quality
CCL and Spiroll was a hollowcore factory in Abuja, hollowcore slab with the absence of
Nigeria for ITB Nigeria Limited, to produce Spiroll cracks or weak spots (on it) ”
slabs for the construction of a new International
Convention Centre in the Nigerian capital.
The Abuja factory produces over 500m2 (5,382ft2)
of high-quality hollowcore slabs per day on 4 x 120m
(394ft) long casting beds, in 5 different depths from
150mm (6in) - 360mm (14in).
Spiroll and CCL supplied both machinery and project
management. Machinery included a universal extruder,
a multi-angle saw and a bed cleaner which allows beds to
be prepared in less than 15 minutes by only one operative.

Hollowcore Solutions
08/09
BENEFITS OF SPIROLL HOLLOWCORE

PROFITABLE DURABLE
Few building materials available today offer the Spiroll hollowcore slabs provide long-term performance
economy, flexibility and reliability of precast prestressed in extremely harsh conditions that could destroy lesser
concrete. The Spiroll hollowcore slab can be utilised materials. They are extremely resilient to deterioration
in many applications that present numerous sales from the weather and the denser the slab, the higher
opportunities in local markets. the fire rating.

FLEXIBLE GREEN
As well as a versatile flooring and roofing application, Spiroll slabs are also the best slab to be used by
Spiroll hollowcore slabs can also be utilised for wall the hugely successful heating and ventilation system
panels. A wall panel conversion kit for the extruder TermoDeck®. The system uses thermal masses to
allows it to be easily converted to make 150mm (6in) store energy in the slabs and is far more cost-effective
and 200mm (8in) deep tongue and groove slabs. than conventional air conditioning systems.

FAST QUALITY
Spiroll hollowcore provides producers with full The Spiroll extrusion process produces the most
control over all the variables which affect the durability, consistent and best quality hollowcore slab. This provides
strength and appearance of the slab. The high quality the ultimate in structural design and flexibility being
and excellent finishes of the slabs reduce site work to entirely compatible with steel, masonry, hollowcore,
an absolute minimum. concrete block and precast concrete beam constructions.

ECONOMICAL
Spiroll hollowcore slabs are up to 30% lighter than
an equivalent in situ floor. Building foundations and
supporting columns/beams can be significantly reduced.
Longer spans and greater loads can also be achieved
with Spiroll slabs.

www.spiroll.co.uk
• High-quality surface finishes
• Long spans
• High load bearing
• Sound insulating
• Fire resistant
• Quality soffit finishes
• Good camber control
• Soffits painted directly
• Good shear capacity
• Used for wall panels

Hollowcore Solutions
10/11
The Spiroll
production system
is an internationally
proven method
for manufacturing
prestressed
hollowcore slabs of
the highest quality.

www.spiroll.co.uk
WHY USE SPIROLL?

Our system is founded on a range • Product quality

of machinery that is reliable, easily • Less cement
maintained, and delivers a consistent • Double casting
product. This guarantees successful • Low scrap rates
projects and a quick return on capital • Good bond retention
investment for our customers. • Optimum bed utilisation
As well as ensuring a quality product, the high frequency • Easy maintenance
vibration utilised in Spiroll extruders minimises
• Off-the-shelf spare parts
production costs such as raw materials, labour and
maintenance. We support our customers with training • Universal extruder
packages and documentation, a team of maintenance
engineers, and off-the-shell spare parts availability.

Hollowcore Solutions
12/13
PRODUCTS

Alongside turnkey solutions for hollowcore production, we provide a wide range

of supporting products:

HOLLOWCORE PRESTRESSING SITE SAFETY

• Hollowcore design/production • Stressing pumps • SlabLock fixing clamps
software
• Stressing jacks • Fall arrest clamps
• Universal extruder saws
• Multi-stressing systems • Edge protection
• Bed cleaners
• Stressing grips
• Casting beds and heating systems
• Stressing cleaning accessories
• Stressing abutments
• Rapidcut
• Hydraulic detensioning systems
• Calibration units
• Concrete distribution skips
• Strand pushers
• Factory lifting clamps
• Slab insulation covers
• Wire/strand dispensers

www.spiroll.co.uk
SERVICES

We also provide a comprehensive range of tailored services to support hollowcore

production and prestressing of precast concrete:

HOLLOWCORE PRODUCTION SUPPORT

Design, consultancy and manufacturing support
is available through our engineering and technical
department:
• Spare parts
• Commissioning, maintenance, servicing, reconditioning
• Prestressing training
• Prestressing safe systems of work and risk
assessments
• Prestressing equipment maintenance, servicing,
calibrations
• Management consultancy contracts
• Hollowcore factory design
• Hollowcore slab technical data
• Wall panel information
• Quality control
• Site fixing
• Bespoke machinery

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14/15
CONTACT US

Find out more about the benefits

of Spiroll hollowcore production
systems - we can provide:
• Detailed appraisal for all aspects of
production
• A payback model comparing the costs
to your proposed output and selling prices

T: +44 (0)1332 365 131

F: +44 (0)1332 291 736
E: [email protected]
W: www.spiroll.co.uk
Spiroll Precast Services Ltd
Kingsway Industrial Park
Derby
DE22 3FP
United Kingdom

www.spiroll.co.uk
HOLLOWCORE
SOLUTIONS
 Grey Matter – www.usegreymatter.com
9073 – DESIGNED AND PRODUCED BY
T: +44 (0)1332 365 131
F: +44 (0)1332 291 736
E: [email protected]

The specifications, information and performance of the products

manufactured by SPIROLL and featured in this publication are presented
in good faith and believed to be correct. Details may be changed without
notice. SPIROLL makes no representations or warranties as
to the completeness or accuracy of the information. Information
is supplied upon the condition that the persons receiving same
will make their own determination as to its suitability for their
purposes prior to use. In no event will SPIROLL be responsible for damages
of any nature whatsoever resulting from the use of, or reliance upon,
information contained in this document. SPIROLL accepts no liability for
any errors or omissions therein.

SPIROLL. 04/2016

www.spiroll.co.uk