At the bustling construction site of the Qinhuangdao–Shenyang Expressway, a state-of-the-art smart precast girder yard stands out as a remarkable sight. Unlike traditional precast girder yards, which are characterized by the din of workers and the roar of machinery, this facility is defined by the precise operation of intelligent equipment and the real-time monitoring and control provided by digital systems. Built by Dongfeng Rail, this smart girder yard is leveraging cutting-edge technology to inject fresh momentum into the high-quality construction of this vital transportation corridor.

Empowering with Intelligence, Revolutionizing Traditional Girder-Construction Methods

Traditional precast girder yards typically suffer from low production efficiency, reliance on manual quality control, and numerous safety risks. The Dongfeng Rail Smart Girder Yard has achieved a comprehensive upgrade of the girder manufacturing process by integrating advanced technologies such as the Internet of Things, big data, and BIM.

“We have built a fully intelligent production line that covers the entire process—from rebar fabrication to concrete placement, curing, prestressing, and grouting,” said the project leader of the Dongfeng Rail Project. At the smart precast girder yard, each prefabricated girder is assigned a unique “digital identity” and its full lifecycle data—from manufacturing to erection—is recorded and tracked via a QR code.

Precision and efficiency in delivering quality projects

In the production of precast girders required for the Qinhuangdao–Shenyang Expressway project, the smart girder yard has demonstrated significant advantages:

The intelligent production line has achieved an automation rate of over 90% for key processes, resulting in a roughly 30% increase in production efficiency and a 25% reduction in labor costs.

The steam curing system automatically adjusts temperature and humidity based on ambient conditions, ensuring stable and controllable concrete strength.

Intelligent tensioning technology enables precise application of prestress, with error control within 1%, significantly lower than the code-specified limit of 5%.

The quality traceability system comprehensively records the production data for each girder, enabling rapid root-cause analysis of any quality issues.

These technical measures have ensured the safe, high-quality, and efficient production of the precast girders required for the Qinhuangdao–Shenyang Expressway, thereby providing a solid guarantee for the overall project schedule.

Green and safe—setting a new industry benchmark

Compared with traditional girder yards, the Dongfeng Rail Smart Girder Yard also excels in environmental protection and safety management:

The site is equipped with dust and noise monitoring systems as well as wastewater treatment and recycling facilities, achieving zero wastewater discharge and controlled dust levels.

All major equipment is equipped with safety monitoring systems, and electronic fences are installed in hazardous areas to effectively prevent safety incidents.

Optimize material transportation routes and reduce the risk of concurrent operations within the yard through an intelligent scheduling system.

These measures not only ensure a green and low-carbon production process but also create a safer working environment for employees.

Supporting the Qinhuangdao–Shenyang Expressway and Advancing the Building of a Transportation Powerhouse

As a vital corridor linking Northeast and North China, the Qinhuangdao–Shenyang Expressway plays a crucial role in promoting regional economic and social development. The successful implementation of the Dongfeng Rail Smart Girder Yard has provided robust technical support for the project and serves as a compelling example of the intelligent transformation of transportation infrastructure construction.

“The Smart Girder Yard not only addresses the pain points of traditional precast girder production but also pioneers a new path toward industrialized and intelligent girder fabrication,” an industry expert commented. “This innovative model holds significant reference value for the future development of highway construction.”

As China’s transportation infrastructure continues to advance toward high-quality development, the successful experience of the Dongfeng Rail Smart Girder Yard is poised to be replicated in more projects, thereby contributing greater intellectual and technological expertise to the country’s drive to become a transportation powerhouse.

Looking ahead, Dongfeng Rail will continue to deepen research and development of smart girder-yard technologies, expand their applications in bridge construction, and drive the advancement of China’s transportation infrastructure toward greater intelligence, efficiency, and environmental sustainability.