Fully automated plant for DST Group in Portugal

To maximize efficiency, quality, and future scalability, DST selected Construx Group as its single-source technology partner. The project brought together the expertise of Construx (formwork and moulds), Weckenmann (automation and carousel systems), Acimex (lifting systems), and CBE (specialized tunnel segment formwork).

Engineering model: modularity, compatibility and throughput stability

The new facility was designed around a clear philosophy: modularity, compatibility, and high production efficiency. It combines prestressing beds, beam moulds, stair and lift-shaft moulds, and a fully automated wall production carousel, allowing DST to manufacture a wide range of structural and architectural precast elements for industrial and residential construction. 

Prestressing lines: heavy-duty infrastructure for structural beam manufacturing

A key feature of the factory is its beam production capability. Construx supplied three 120-meter prestressing beds, including heavy-duty systems equipped with 600-ton and 1,000-ton abutments. These production lines allow DST to efficiently manufacture high-load structural beams with excellent repeatability and fast setup times. 

Modular beam formwork: delta, I-beam and rectangular

To support maximum flexibility, the plant includes several modular beam formwork systems for delta beams, I-beams, and rectangular beams. Thanks to interchangeable components and standardized connections, moulds can be reconfigured quickly to suit different beam geometries, helping DST respond efficiently to varying project requirements. 

Multiple Precast Solutions

The factory also incorporates advanced solutions for columns, stairs, lift shafts, and wall elements. Bibat hydraulic battery moulds enable efficient production of columns and beams, while the Flexcaster stair mould allows rapid and precise adjustment of stair dimensions through electrically controlled actuators. The Flexbox lift-shaft mould offers adjustable dimensions and hydraulic shrinking corners, making demoulding faster and more efficient. 

For wall and panel production, a 20 x 4-meter tilting table provides high-frequency vibration and precise moulding, ensuring excellent surface quality and uniform compaction. 

Automated Carousel System

At the heart of the plant lies a fully automated Weckenmann carousel system. Equipped with 20 production pallets, the system integrates robotics, digital process control, automated storage, and intelligent material flow. DST already plans to expand the system to 28 pallets, further increasing capacity. 

Automation plays a major role throughout the factory. A shuttering robot automatically places and removes magnetic formwork with millimetre accuracy, while a concrete distribution system ensures precise dosing and consistent panel quality. Additional stations for curing, surface finishing, cleaning, and oil spraying help maintain high product standards while reducing manual labour. 

The Figueira da Foz project demonstrates the advantages of an integrated approach. By working with a single engineering partner, DST benefits from equipment that is mechanically and digitally compatible, simplified maintenance, streamlined commissioning, and a clear path for future expansion. The result is a highly efficient, modern precast concrete facility designed to meet both current and future production demands.