Case study: motor spindles for concrete spraying and centrifugation (pipe manufacturing)
Brochexpress developed, for a concrete industry manufacturer, motor spindles for concrete spraying in the production of reinforced concrete pipes. This project illustrates our ability to step outside conventional machining and design spindles suited to very different manufacturing processes.
A project outside the conventional scope of the machining motor spindle
TLDR: Manufacturing reinforced concrete pipes uses centrifugation or spraying processes, in which concrete is formed inside a rotating cylindrical mould. For a manufacturer of reinforced concrete pipes, Brochexpress designed motor spindles suited to this application, far removed from the metal or composite machining that is the usual core of our business.
Manufacturing reinforced concrete pipes uses processes very different from traditional machining: centrifugation, where a rotating cylindrical mould receives concrete that is pressed against its walls by centrifugal force, and spraying, where concrete is projected inside the mould to form the pipe walls. Both processes rely on precise, controlled rotation of the mould or of the spraying element, with constraints very different from those of metal or composite machining: abrasive and heavy material, production cycles repeated continuously on industrial lines, and a demanding working environment (cement dust, moisture). For a concrete industry manufacturer, a major player in construction materials, Brochexpress designed motor spindles specifically adapted to this concrete spraying application, a project that required adapting our motor spindle design expertise to a specification far removed from our usual applications.
What this project demanded of our engineering office
TLDR: Designing a motor spindle for concrete spraying means rethinking several usual design parameters — rotation speed, sealing, abrasion resistance — to match the constraints specific to forming concrete, very different from those of precision machining.
Designing a motor spindle for a concrete spraying process required our engineering office to rethink several usual design parameters. Rotation speed, first: it bears no comparison with that of a precision machining motor spindle, since concrete forming processes run at far more moderate speeds, but with significant torque and mechanical loads linked to the weight and viscosity of the material. Sealing, next, has to cope with an environment particularly aggressive for mechanical components: abrasive cement dust, water spray, constant humidity — conditions far removed from an air-conditioned machining workshop. Finally, resistance to abrasion and premature wear required particular attention to the choice of materials and spindle protection systems, to guarantee a service life compatible with the industrial production rates expected by a concrete industry manufacturer.
Lessons transferable to other projects
- Motor spindle design is not limited to machining: the principles of rotation, sealing and power transmission apply to many industrial processes
- Every production environment has its own constraints, to be built into the design phase rather than discovered afterwards
- The experience gained on this type of project strengthens our ability to assess the feasibility of new applications outside the conventional field of machining
- Close collaboration with the end customer (production constraints, throughput, environment) is decisive in the success of such a specific project
An experience that illustrates our ability to step outside the usual scope
This project illustrates a sometimes little-known dimension of our business: beyond repairing and manufacturing spindles for precision machining, our engineering office is able to design rotation solutions for a wide variety of industrial processes, whenever the specification justifies it. This experience directly informs our thinking on other emerging applications, notably robotic concrete additive manufacturing, a fast-growing sector we are watching closely.
Frequently asked questions
Is this type of project representative of your main business?
No, our core business remains the repair and manufacture of machining spindles and motor spindles. This project illustrates our ability to step outside that scope when a customer comes to us with a specific need.
Can you support a similar project in another industrial sector (food processing, chemicals, etc.)?
We study each project case by case according to the technical constraints presented — contact us to assess the feasibility of your need.
Did this project lead to series production or to a one-off prototype?
The contractual details of our customer projects remain confidential, but our manufacturing model covers both one-off pieces and small batches.
Brochexpress, expertise that goes beyond conventional machining
Our engineering office designs spindle and motor spindle solutions matched to a wide variety of industrial processes, beyond precision machining alone.
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