Modular Architecture and Construction Industrialilzation

For several years, Moldtech has introduced to the market a new generation of 3D hydraulic moulds which are used for the construction of prison cells and residential buildings.

Prefabricated Prefinished Volumetric Construction “PPVC”, is a construction method by which independent three-dimensional modules are fabricated, completed with internal finishes, installations, and accessories in an industrial factory, and are transported and installed on the final site, where they are structurally connected to each other and to the general installations piping lines.

There are many reasons why this modular architecture system is booming, some of the most important are:

Improved Productivity: PPVC can improve productivity by up to 40% in terms of manpower and time savings, depending on the complexity of the projects.

Better Construction Environment: As the bulk of the installation activities and manpower are moved off-site, it minimises dust and noise pollution and improves site safety.

Improved Quality Control: Off-site fabrication in a controlled factory environment can produce higher quality end products.

Due to the significant experience in various projects both in Asia, as well as in the Middle East, Europe and South America, Moldtech has been selected by one of the most important construction companies in Europe to be the supplier of the three-dimensional prison cell prefabrication system which will be used in the production of prison modules for various projects and with a variety of dimensions.

The PPVC moulds allow our client to precast the walls and the upper slab of said prison cells, which once lifted from the mould are moved to a finishing table where the lower slab is incorporated which allows the module to be closed on its 6 faces and to pass to finishes and equipment. This working system avoids the "turning" of the three-dimensional cells part.

One of the big challenges of this project was that the prison cell production system had to adapt to various projects, and therefore allow a change in dimensions in the length and width of the cells, in addition to allowing changes of symmetry on its sides. This three-dimensional mould, with an hydraulic folding inner mould, was designed as a machine adaptable to various configurations, both in size and shape. This working model allowed the customer to reduce the investment and to be able to cope with different jobs with the same PPVC cell production system.

Once the three-dimensional concrete modules have been removed from the mould, the finishes are carried out, the installations are incorporated and the furniture is installed, in a fully industrialized production line, where operators and technicians perform repetitive and controlled tasks like in a car factory, that makes it possible to check the quality of each step of the process and to obtain prison cells of a very high level of quality.

Moldtech also worked on the installation, commissioning, and training of the client's staff, in addition to assisting the client in the processes of adjusting dimensions to adapt to new projects.

With this project, Moldtech reaffirms itself as the undisputed world technological leader in prefabricated modular construction PPVC, and takes a new step in the construction industrialization development.