Abetong - Long Line System
The Abetong Long Line System was originally developed in 1960. It is characterized by the use of long casting beds in which sleepers are cast as continuous beams using quadruple moulds placed one after the other. The sleeper beams are left to cure inside the mould overnight and the day after cut into individual sleepers using a diamond cutting unit. The production method of Abetong starts with handling of incoming raw material and ends first when the sleepers are equipped with fastening components and ready to be loaded onto the railway wagons or trucks.
Continuous development has over the years secured a position of the Abetong Long Line System as the overall most optimized method to produce prestressed concrete sleepers for main lines and turnouts. The focus areas in all our processes are related to
Quality, Efficiency, Flexibility, Safety and Work Environment
Quality - is the key to develop a successful business. This is assured by choosing well proven production methods with international track records in combination with a sleeper design being optimized for the national requirements, the sleeper standard being valid as well as the production method utilised. When using the Abetong know-how our Clients have invested in the best possible conditions for top quality performance.
Efficiency - a major expense in the overall cost for concrete sleepers is the labor cost. The more rational and mechanized production method the lower cost and thereby a stronger competitiveness. There are savings to be done in the whole process from raw material logistics, through production process ending with the sleeper handling logistics at stockyard and loading.Due to the reliability of a well proven technology, factories utilizing Abetong Technology have a minimum of production stops and rejects. Our production equipment utilizes well renowned brands of spare and ware parts with branch offices around the world. With the Abetong Long Line System the man hour required per sleeper as well as the breakdown stops will thereby be kept to a minimum.
Flexibility – Through the vast experience of Abetong in establishing and operating sleeper production plants the company has gained extensive knowledge in producing sleepers. It relates to a wide range of various geographic areas with significantly different conditions. In areas with high cost for labor our fully mechanized system makes it feasible to produce sleepers with less than 0,1 man hours per sleeper. All work processes normally being labor intensive utilizes specially designed equipment to minimize the human contribution.In other geographic areas where the cost of labor is low, Abetong could offer less mechanized system, with lower investment cost but in turn with an increased work force. Abetong could always customize the production unit after the conditions and request of our Clients.
Safety – is the one aspect never being negotiable by Abetong. Safety is a leading star throughout our entire know-how. Not only production equipment but also the entire process of manufacturing is characterized by Safety first The safety regulations issued by the European Community sets strict requirements on any supplier of equipment within Europe. These regulations are the minimum of requirements followed by Abetong independent on geographic market. For Abetong safety is crucial both in terms of our equipment design as well as in terms of the precautions during the processes of producing of sleepers. The equipment and its operation have been thoroughly studied to evaluate possible risks from which safety devices has been introduced to eliminate the same.
Work Environment – in a plant making precast concrete it is essential to minimize the workload at monotonous processes to avoid injuries among the labor force. This will also become vital in order to attract the younger generation in future employment. In the Abetong Long Line System the processes are designed to eliminate all workload which could lead to wear. The Abetong Long Line system has therefore been designed to allow for the best possible work environment. The casting beds are optimized in height and limited in width to minimize cramped position during preparation of casting moulds. All heavy and ungainly processes are mechanized and handled by equipment The Abetong Technology consists of a set of specially designed equipment, machinery and devices which together with belonging work instructions and procedures as well as sleeper design knowledge creates a rational method to manufacture prestressed concrete sleepers of high and even quality to a minimum of cost.