Polyurethane T Beam Stop Ends for Prestressed Concrete Manufacturing
Manufacturing prestressed concrete T beams is a demanding process. High-tension steel wires, intense vibration, heated casting beds, curing concrete and heavy de-moulding forces all place significant demands on the components used throughout production.
With more than 25 years of specialist design experience, Bonaprene manufactures bespoke polyurethane T beam stop ends designed specifically for the demanding conditions found in prestressed concrete manufacturing.
What Are T Beam Stop Ends?
T beam stop ends, sometimes known as T beam rubbers, are used during the casting of prestressed concrete T beams to form the ends of the finished beam with the floor beam lengths determined by the location of the stop ends.
They are fitted during casting bed preparation and need to withstand the pressures and conditions associated with concrete production. Once the concrete has cured, the stop ends must be removed efficiently so the beam can be lifted, turned and moved without unnecessary disruption to production.
Bonaprene’s polyurethane Tee Beam Stop Ends are designed to make fitting easier during bed preparation while facilitating access for lifting equipment during de-moulding and beam turning.
Why Choose Polyurethane T Beam Stop Ends?
Prestressed concrete manufacturing is an aggressive environment. Stop ends can be exposed to vibration, impact, heat, moisture, concrete and repeated mechanical forces during installation and de-moulding.
Polyurethane offers an effective combination of toughness, flexibility, resilience and durability, making it well suited to reusable components used in demanding concrete manufacturing environments.
Bonaprene has more than 25 years of experience designing specialist polyurethane solutions and manufactures bespoke polyurethane mouldings for demanding industrial applications.
Easier Installation During Bed Preparation
Efficient production starts with efficient bed preparation.
Bonaprene polyurethane T-beam stop ends are designed for straightforward fitting, helping operators prepare casting beds efficiently before pouring concrete.
Because the stop ends are manufactured for the required application, the design accommodates individual beam profiles and prestressing wire positions.
Bonaprene have over 75 designs of tee beam stop ends, making them suitable for 150mm, 175mm and 225mm tall concrete floor beams. And depending on the stressed steel wire positions, we offer 1-piece and 2-piece tee beam stop ends.
Easier De-Moulding and Beam Turning
De-moulding is one of the most demanding stages of T-beam production.
Once the concrete has cured, stop ends need to be removed efficiently without damaging the finished beam or unnecessarily delaying production.
The flexibility of polyurethane helps make this process easier. Bonaprene’s T beam stop ends are designed to facilitate access for lifting equipment and make beam turning more straightforward during de-moulding.
Bonaprene stop ends accommodate their removal the day of the concrete cast or the day after and offer steel box section lifting handles; triangular steel lifting handles; steel plate lifting handles and harness fabric lifting handles to suit your specific need.
Clean, Accurate Beam Ends
The quality of a stop end can directly affect the quality of the finished concrete beam.
A correctly designed polyurethane stop end, helps create a consistent and well-defined beam-end profile, potentially reducing defects and the amount of manual hand-finishing required.
For manufacturers producing large quantities of prestressed concrete beams, improving consistency across production cycles can provide valuable productivity benefits.
A Durable Alternative to Polystyrene
Polystyrene has traditionally been used for certain concrete casting applications, but disposable materials can create additional handling, cleaning and replacement requirements.
Polyurethane provides a durable, reusable alternative to polystyrene.
Bonaprene polyurethane stop ends are designed for repeated use in demanding production environments, helping manufacturers reduce the frequency of replacement and minimise disruption to production.
Depending on the application and operating conditions, Bonaprene polyurethane T beam stop ends can provide a service life of four years or more.
Built for Prestressed Concrete Manufacturing
Prestressed concrete T beam production combines several challenging conditions within one manufacturing environment.
These can include:
- High-tension steel wires
- Heated casting beds
- Intense vibration
- Concrete curing
- Repeated component handling
- Heavy de-moulding forces
- Lifting and beam turning
This makes the durability and design of the stop end particularly important.
Bespoke T Beam Stop Ends for Your Exact Profile
Not every prestressed concrete T beam is the same.
Beam dimensions, profiles, prestressing wire positions and casting-bed configurations can vary between manufacturers.
That’s why Bonaprene manufactures bespoke polyurethane T beam stop ends rather than relying solely on standard components.
The in-house design and manufacturing process allows components to be developed around individual production requirements.
Bespoke options can include:
- Individual T beam profiles
- Specific beam dimensions
- Prestressing wire positions
- One-part stop ends
- Two-part stop ends
- Replacement stop ends for existing systems
- Different polyurethane hardnesses
- Components designed around existing casting beds
By designing the stop end around the application, manufacturers can achieve a solution that integrates with their existing production process.
One-Part and Two-Part T Beam Stop Ends
Different beam profiles and manufacturing systems can require different stop-end configurations.
Bonaprene manufactures both one-part and two-part Tee Beam Stop Ends, allowing the design to be matched to the individual application.
This bespoke approach means manufacturers do not have to compromise their production system to accommodate an unsuitable standard stop end.
Why Polyurethane?
These characteristics make polyurethane particularly useful for components that need to withstand repeated use and demanding industrial conditions.
For concrete manufacturers, polyurethane can provide:
- High durability
- Excellent resilience
- Resistance to repeated flexing
- Good impact performance
- Long-term reusability
- Bespoke manufacturing options
- Different material hardnesses
The result is a reusable component designed for the demands of repeated concrete production.
Reduce Downtime and Replacement Costs
The cost of a T beam stop end isn’t simply the initial purchase price.
Manufacturers also need to consider:
- How frequently the component needs replacing
- Production downtime
- Manual finishing
- Cleaning requirements
- Difficult de-moulding
- Labour during bed preparation
- Damage caused during removal
- Disposal of consumable materials
A durable polyurethane solution can help address several of these factors.
Why Choose Bonaprene?
Bonaprene has more than 25 years of experience designing and manufacturing polyurethane products for demanding industrial applications.
For the construction and concrete sector, this includes Slotted Post Moulds, Specialist Release Agents, Universal Multi-Holed Fence Post Mould, and Recessed Post Moulds.
When you work with Bonaprene, you benefit from:
- More than 25 years of specialist design experience
- Bespoke polyurethane engineering
- In-house design and manufacturing
- One-part and two-part stop-end solutions
- Durable and reusable components
- Designs tailored to individual beam profiles
- Solutions designed around prestressing wire positions
- Worldwide delivery
- Experienced technical support
Bonaprene also work with core suppliers in the beam and block flooring industry such as MACFAB, Bianchi Casseforme and Roco Concrete Machinery
Improve Your T Beam Manufacturing Process
A T beam stop end may be a relatively small component, but its performance can have a significant effect on the wider production process.
The right polyurethane T beam stop ends can help make bed preparation easier, facilitate de-moulding, improve consistency and reduce reliance on disposable materials.
For manufacturers producing prestressed concrete T beams, polyurethane provides a combination of durability, flexibility, reusability and bespoke engineering that makes it an effective alternative to traditional stop-end materials.
If you’re experiencing problems with difficult de-moulding, damaged stop ends, excessive hand-finishing or frequent replacement, it could be time to consider a more durable solution.
Get a Quote for Polyurethane T Beam Stop Ends
Bonaprene offer on-site visits for bed surveys; design advise and usage advise such as fitting and lifting processes.
Whether you’re looking for replacement T beam rubbers, a reusable alternative to polystyrene or a completely bespoke stop-end solution, Bonaprene’s technical team can discuss your requirements.
Why Use Bonaprene For Your T Beam Stop Ends?
About Bonaprene
The UK’s leading producer of polyurethane products, we manufacture, refurbish and supply components for a wide range of uses.
