Recently, the intelligent bridge production line independently designed and newly built by Beijing Yugou Precast Concrete Engineering (hereinafter referred to as BYPCE) successfully completed commissioning and has now entered stable and mature operation. As the most advanced bridge production line in the Beijing–Tianjin–Hebei region, its launch marks the Group’s entry into a new development phase featuring intelligent efficiency and green, low-consumption manufacturing, injecting strong momentum into regional transportation infrastructure construction.

1. Independent R&D Breaks Bottlenecks, Craftsmanship Revitalizes Tradition

The newly completed intelligent bridge production line—ranging from core planning to technical details—was fully designed in-house by the group of BYPCE. Targeting the core objective of breaking traditional production bottlenecks and improving end-to-end efficiency, the project team boldly introduced the internationally advanced mobile formwork (mobile casting bed) production process, while optimizing multiple sets of key supporting equipment based on extensive industry experience.

An independently operated high-efficiency rebar processing center, fine-tuned by BYPCE’s technical team, enables precise rebar processing and rapid turnover. Pre-fabricated top-slab rebar cages, assembled using BYPCE’s proprietary assembly workflow, significantly reduce on-site assembly time. The two 21-meter tower-type distributing systems are another original innovation: they simultaneously cover a 1,385 m² working area below 4.2 m delivering concrete at up to 60 m³/h, fully resolving the long-standing issues of low casting efficiency and uneven distribution in traditional operations.

To meet seasonal production requirements, the line features a newly developed “four-season adaptive” curing system, also designed in-house. In winter, an automatic induction-type steam curing system intelligently adjusts steam output based on ambient temperature to ensure curing quality. In summer, the system switches to a high-transparency, solar-enhanced natural curing mode, using clean energy to achieve efficient curing while lowering energy consumption and ensuring strength. Additionally, the group has conducted an integrated upgrade of the tensioning system. Through intelligent control and multiple safety mechanisms, the system greatly improves the safety and stability of tensioning operations, ensuring consistent product quality.

2. High-Efficiency Implementation Demonstrates Strength, Dual-Line Operation Secures Capacity

From conceptual planning to operational launch, the project team of BYPCE pursued a development approach centered on high standards and high efficiency. As the most advanced bridge production line in the region, its design underwent repeated refinement in process flow and equipment layout. Civil works, equipment installation, and commissioning were completed in only 95 days, nearly 30% faster than the average. The successful production of the first girder showcased BYPCE’s execution power in both speed and quality.

Notably, on the south side of the intelligent line, the traditional fixed casting-bed line continues to operate steadily, currently producing 30–40 m box girders. This line is responsible for manufacturing 1,800 box girders, T-girders, and hollow slabs for the G95 project. The dual-line model—"intelligent + traditional”—not only ensures production capacity for major projects but also serves as a regional demonstration, accelerating process upgrades across the group.

3. Four Core Advantages Set a Benchmark, Leading Smart Construction in the Region

Compared with traditional production lines, BYPCE’s intelligent bridge production line stands out as a new benchmark in regional bridge prefabrication with four key advantages:

Significantly higher capacity: Daily output reaches seven box girders, a 40% increase over traditional lines, meeting peak supply demands for large-scale projects.

Substantially shorter production cycle: End-to-end automated coordination reduces the production cycle from 36 hours to 24 hours, achieving a major leap in efficiency.

Lower energy consumption: The innovative low-energy curing process combined with a self-developed intelligent energy-management system reduces per-unit energy consumption by 25% compared to the industry average.

Leading automation: A fully digitalized workflow is established from raw material entry to final product dispatch, covering rebar processing, concrete casting, automated curing, intelligent tensioning, and grouting. Equipped with digital simulation, digital-twin technology, and an integrated processing-control center, the system enables real-time production monitoring, process optimization, and “precise, visualized, and intelligent” girder manufacturing.

4. Excellence Through Detail, Innovation for Long-Term Growth

Refined engineering and independent innovation are reflected in every detail of the production line. Four mobile formwork beds, each 38 meters long, were optimized through multiple design iterations to support automated production of both 30-meter and 35-meter box girders without switching equipment—eliminating the “girder-type switching barrier” typical of traditional lines. The mobile beds maintain a stable operational speed of 7.5 meters per minute, supported by a three-stage stability control system that delivers industry-leading accuracy and smoothness. Each bed’s automated side-form opening/closing mechanism is powered by 16 hydraulic units, while the 6+1 stainless steel panel system ensures rigidity, flatness, durability, and high-quality girder appearance and structural integrity.

As the most advanced bridge production line in the Beijing–Tianjin–Hebei region, the successful commissioning and stable operation of BYPCE’s independently designed intelligent production line is a powerful testament to the group’s innovation capabilities. It represents a key step in driving the regional bridge prefabrication industry toward intelligent, green, and efficient transformation.

Looking ahead, BYPCE will continue to deepen its presence in the field of intelligent construction, delivering higher-quality products and more efficient services, and contributing robust support to national transportation infrastructure development.