Extruder Mouldless Hollow-Core casting — The Modern Standard of Quality and Efficiency
In modern construction, the extruder-based mouldless hollow-core forming technology has become a benchmark for efficiency and product quality in precast concrete manufacturing.
Using this method allows producers to reduce labor costs, speed up production cycles, and ensure consistent quality of hollow-core slabs.
In this article, we explain how the technology works, where it is used, what advantages it offers, and why you should choose our company for its implementation.
How the Mouldless Forming Technology Works: Precision, Speed, and Cost Efficiency
The extruder hollow-core forming process works as follows: The concrete mix is fed into the extruder hopper and, using a screw system, is pressed under high pressure through a compacting unit along a casting bed, forming the desired cross-section of the product. The compacting unit ensures uniform material distribution, air removal, and a dense, homogeneous structure of the finished product. This method eliminates the need for traditional formwork installation and removal, which significantly reduces production time and cost. Hence the term “mouldless forming” — it is the key distinction from conventional concrete casting methods.
The technology allows for producing slabs of various heights (approximately 80 mm to 600 mm) and widths (up to 2400 mm), depending on the equipment model. Overall, the benefits are higher productivity, reduced formwork expenses, and greater flexibility in manufacturing.
Where the Extruder is Used Real-World Applications
The mouldless hollow-core forming extruder is used for producing hollow-core floor slabs, wall panels, solid slabs. For instance, TDM Engineering Oy (Finland) has installed extruders on production lines in Ukraine for hollow-core slabs with a width of 1200 mm and heights of 220 mm and 300 mm.
In other regions of the CIS and Asia, the equipment is used for producing long-span hollow-core slabs and concrete piles. Thus, the technology is equally valuable for residential and commercial construction (floor slabs) as well as infrastructure projects (piles, beams, panels).
Advantages of Mouldless Hollow-Core Forming Proven Facts
- Production Speed – Forming rates reach 1.4–3.5 m/min, depending on slab type and concrete mix.
- No Formwork Required – Eliminates complex removable moulds, reducing labor and cycle time.
- Product Size Flexibility – Slabs can vary in height (80–600 mm) and width (300–1200/1500/2400 mm), depending on equipment configuration.
- Superior Concrete Quality – The screw and compaction system ensure uniform density and structure.
- Low Operating Costs – Simple design without complex shafts or gearboxes, easy maintenance.
- Wide Application Range – Suitable for slabs, beams, piles, and wall panels — a high-return investment for any precast plant.
These advantages allow precast concrete manufacturers to reach a new level of productivity and competitiveness.
TDM Extruders — A Reliable Solution for Your Precast Concrete Production
If you want to integrate the mouldless hollow-core forming extruder technology into your plant or production line, we offer customized turnkey solutions. Our company provides full support: equipment selection, delivery, installation, staff training, and technical service.
We deliver comprehensive integration with warranty support, increasing your plant’s productivity through technology already proven across Europe and the CIS.
Contact us today to gain a technological edge for your enterprise.
FAQ: Mouldless Hollow-Core Forming Technology
- What is a hollow-core extruder for mouldless concrete forming?
It’s equipment that forms hollow-core concrete slabs without traditional formwork.
The mix is fed through the extruder screws, compacted, and shaped directly on the casting bed.
- Why is mouldless forming more efficient than conventional casting?
It eliminates formwork installation/removal, reduces labor costs, speeds up production, and ensures consistent product geometry.
- What products can be made using a hollow-core extruder?
Main products include hollow-core floor slabs, wall panels, beams, and piles.
The equipment can be configured for various sizes and shapes.
- Where is the technology used?
It’s implemented at precast concrete plants producing elements for residential, commercial, industrial, and infrastructure construction.
- What are the advantages of TDM extruders?
TDM extruders are known for reliability, high forming speed (up to 3 m/min), easy maintenance, and the ability to produce slabs of different dimensions with low energy consumption.
- Why should I buy equipment from your company?
We provide a complete solution — from equipment selection and supply to installation, training, and technical support.
This ensures a smooth production start-up and fast return on investment.