Intelligent Precast Beam Yard

The Smart Beam Yard is an intelligent, digital “superfactory” in the field of bridge prefabrication. 
With BIM, the Internet of Things (IoT), big data, AI, and digital twins at its technological core, it enables automated production, digital management, and intelligent decision-making throughout the entire process of prefabricated box girders (T-beams)—from raw materials to rebar processing, casting, curing, post-tensioning, storage, and transportation and installation. 
The core objective is to upgrade traditional, labor-intensive beam production—relying on manual labor and experience—into data-driven, precise, controllable, and highly efficient industrialized smart manufacturing.

Functional Zones (Seven Standard Modules)

1. Smart Reinforcement Processing Area: Automatic cutting, bending, and welding robots; smart tying production line

2. Beam Manufacturing Area: Mobile workbenches, hydraulic smart formwork, automatic vibration, and concrete placing machines

3. Smart Curing Area: Constant-temperature steam curing, closed-loop spraying, automatic temperature and humidity monitoring, and curing trolleys

4. Prestressing Area: Intelligent tensioning, intelligent grouting, precision force measurement, automatic data upload

5. Beam Storage Area: Digital beam storage, intelligent transfer, one-click beam location, automatic inventory

6. Testing and Quality Control Area: Automatic concrete batching, real-time strength monitoring, non-destructive testing

7. Central Control Center (Brain): Digital twin display, remote monitoring, data analysis, early warning and dispatch

Four-Layer Architecture

• Perception Layer: Sensors, cameras, RFID, positioning chips, IoT devices

• Data Layer: End-to-end data collection, storage, cloud uploading, and quality traceability

• Platform Layer: BIM + Digital Twin, virtual-physical synchronization, 3D visualization, and simulation

• Application Layer: Production management, equipment operation and maintenance, quality control, safety monitoring, and intelligent decision-making

• Automated rebar production lines, welding robots

• Intelligent hydraulic formwork (one-button opening and closing)

• Smart compaction and automatic concrete placement systems

• Smart curing systems with constant temperature and humidity control

• Smart post-tensioning/grouting systems (Class 0.1 precision)

• Smart beam transfer, beam transport vehicles, and beam hoists

• Digital twin central control platform

Reductions

• Labor costs reduced by 30%+: Automation reduces staffing, unmanned operation

• Safety incidents reduced by 90%: AI monitoring, violation alerts, remote control

• Energy/Material Consumption Reduced by 15%–20%: Precise Mixing Ratios, Optimized Curing

Increases

• Efficiency Increased by 50%–100%: Cycle Time Reduced from 7 Days to 3–4 Days, Monthly Production Doubled

• Quality Pass Rate of 98%+: Consistent Reinforcement Cover, Tensioning Accuracy, and Strength

• Upgraded Management: End-to-End Visibility, Data Traceability, Remote Command, and Intelligent Production Scheduling

Key Differences from Traditional Beam Yards

• Traditional: Labor-intensive, experience-based management, fragmented data, inconsistent quality, low efficiency, large footprint

• Smart: Automated production lines, digital twins, closed-loop data management, end-to-end traceability, high efficiency and resource conservation, green and low-carbon

• Prefabrication of highway and high-speed rail/railway bridges

• Urban elevated roads, subways, and intercity railways

• Prefabrication yards for large-scale river- and sea-crossing bridges

• Prefabricated bridges and industrialized construction demonstration projects