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PRECAST CONCRETE ELEMENTS116 CPI %u2013 Concrete Plant International %u2013 4 | 2025 www.cpi-worldwide.comConstrux-Weckenmann announces the successful commissioning of a fully integrated carousel-based production system for prestressed railway sleepers in Romania. Developed to support the increasing demands of modern rail infrastructure, the facility is engineered to deliver high-volume, high-precision manufacturing of Type B70 sleepers. With a strong emphasis on automation and scalability, the new system brings together high mechanical performance and intelligent control to create a reliable, future-ready production line.Engineered for Productivity: 189,000 Sleepers per YearThe heart of the installation is a high-capacity carousel plant equipped with 300 quadruple sleeper moulds and 20 synchronized workstations. The circulation of moulds is seamlessly managed to ensure optimal cycle times and minimize idle phases. To support curing requirements, the system includes four tunnels with a rope pull system, each housing multiple positions, resulting in a total of 300 mould capacity within the curing zone. This enables uninterrupted production and supports year-round operation under controlled, consistent conditions.Key Performance Metrics%u2022 Annual production capacity: ~189,000 sleepers%u2022 Output per shift: 756 sleepers%u2022 Operating schedule: 1 shift per day, 250 days per year%u2022 Facility dimensions: 73 m (L) x 23 m (W)Automated Workflow for Scalable OutputThe sleeper production process is fully streamlined through an automated and modular workflow. A dual-direction mould transport system, operating longitudinally and transversally, allows continuous mould circulation through all production stations. Mould preparation is handled with manual oiling and placement of built-in parts, providing flexibility and precision in set-up. Rebar placement is facilitated by a semi-automated system that ensures accurate positioning while significantly reducing manual workload.Prestressing is managed through fully automated tensioning and detensioning systems, enabling consistent mechanical performance and compliance with railway specifications. Once reinforcement is in place, concrete is introduced using a 4-screwed concrete spreader, designed for even distribuNext-Generation Sleeper Production with Automated B70 Carousel System in RomaniaConstrux Weckenmann, 8531 Hulste, BelgiumSleepers type B70 Mould manipulator and demoulding station, fully automated detensioning machine (background)