X P R E C A S T T E C H N O L O G Y

B Y IM Z H OLDIN G

T H E M O ST SU S T AI N AB LE & AF F O R D AB LE P RE CA ST SOL UT ION

 introduction
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join the revolution

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unique xprecast advantages

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xprecast vs traditional precast:

material & time ratios savings
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productivity of xprecast system

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production process
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how the system works

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documentation
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XPrecast by IMZ
the biggest revolution in the built environment

INTRODUCTION
XPRECAST: A revolutionary shift in the industry landscape
Imagine a moment in history, a revolution that reshapes the very
foundation of the construction industry. On the 21st of December
2023, IMZ Holding unveiled XPrecast – a game-changer that
stands as the biggest revolution in the global precast industry.

Through our groundbreaking XPanel Precast division, XPrecast emerged,

ushering in an era of unparalleled transformation. This revolutionary
3D panel technology, exclusively produced by XPanel, propels off-
site precast companies to new heights of competitiveness. The result?
A remarkable reduction of over 50% in material costs and a boost in
productivity by more than 40%, all achieved with the same resources.

Traditionally, off-site precast companies represent less than 10% of

the global market, facing hurdles such as being 20% more expensive
as compared to the predominant “in-site” building systems. This cost
barrier has impeded the growth of this market, particularly in affordable
building, which constitutes over 90% of the global construction market.

Enter XPrecast – a technological marvel that transcends limitations.

With XPrecast tech, any off-site XPrecast company can instantly slash
costs, becoming the most competitive player in their market. This
isn’t just a reduction, it’s a revolution that liberates vast resources,
redirecting them towards a technology capable of surpassing
traditional building systems and yielding incredible profits, through
efficient execution, reduced costs and speed of production.

IMZ Holding’s XPrecast isn’t just a solution; it’s a seismic shift in the industry
landscape, which will become the preferred construction technology
moving forward.
Join us as we rewrite the rules, empowering companies to not only survive
but thrive in the dynamic world of construction.

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XPRECASTH BY IMZ HOLDING
 join
the revolution

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XPRECAST TECH BY IMZ HOLDING
 v
join the revolution
the biggest revolution in the built environment

XPanel have began a revolution in the Precast industry,

our bespoke and exclusive technology will elevate
any PreCast company to new levels of efficiency and
profitability. XPrecast is the revolution that the industry
has been waiting for, we offer the opportunity to join our
journey to create a more affordable and sustainable
Precast allowing competition with traditional execution,
opening the doors to increased business opportunities
and market penetration.

KEY CONSIDERATIONS:
• With continued labour shortage, we will drive your requirement
down by 70%.
• Our panel configuration ensures your panel weight will reduce
by 50% without compromising its technical performance.
• We will increase your operational efficiency leading to reduced
operation cost (OPEX).
• XPrecast will use significantly less reinforcement and concrete
than your conventional PreCast, with major improvement on
your Return on Investment.
• XPrecast shall create 80% factory automation immediately
with your current conventional Precast factory within 6 months.
• With lighter, easier panels and increased logistic opportunity,
the potential sustainability and environmental impact will
bring the Precast solution back as a more commercially viable
execution method across the globe.

Be the pioneer with XPanel and drive the Precast industry

as the dominant execution within the market. Our goal is
not to compete with other PreCast companies but to gain
market share in the traditional execution by becoming
competitive and delivery superior quality across all
sectors.

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XPRECASTH BY IMZ HOLDING
 unique XPrecast
advantages

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XPRECAST TECH BY IMZ HOLDING
 unique XPrecast advantages

50% REDUCTION 55% REDUCTION OVERALL 80% REDUCTION NO NEED

OF CONCRETE
100 mm total concrete thickness
in XPrecast vs 150 mm total
concrete thickness in traditional
precast
OF STEEL CONSUMPTION IN WORKING HOURs FOR MANUFACTURING FOR CRANES
Only 45kg/m3 steel Receive & assemble. EPS and steel During production, panels can
consumption in XPrecast as is placed at the same time with no be moved by hand, freeing up
compared to over 100 kg/m3 in additional cuts at precast facility the use of the factory cranes
traditional precast (customized panels)

EPS CONTROLLED TIME SAVING 50% reduction

IN 3D STEEL TRUSS
Special spacers designed and
patented by Xtools included in
the panel to keep EPS precisely
centered in the 3D truss
ON SITE INSTALLATION storage area
Reduction in crane capacity from The reduction of steel rebar
80 t to 50 t lifting weight and longer reduces the storage area by
boom length over 50%

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XPRECAST TECH BY IMZ HOLDING
 unique XPrecast advantages

TRANSPORTATION THE MOST SUSTAINABLE

SAVINGS SYSTEM WORLDWIDE
Reduction of diesel consumption Reduction of concrete, steel and
due to lighter wall panels energy consumption reduces the
carbon foot print by 235 kg CO2/m3
concrete used in traditional precast

35-40% increase 30-40% COST REDUCTION ZERO COST NO NEED FOR

of productivity IN COSTS AS COMPARED WITH OF IMPLEMENTING MODIFICATION
IN THE PRECAST FACTORY THE TRADITIONAL PRECAST XPRECAST TECHNOLOGY IN THE PRECAST FACTORY

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XPRECAST TECH BY IMZ HOLDING
 XPrecast vs.
Traditional Precast · MATERIAL AND TIME RATIOS SAVINGS ·

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XPRECAST TECH BY IMZ HOLDING
 XPrecast material savings
vs. Traditional Precast

INSULATED EXTERNAL PERCENTAGE

XPRECAST
TRADITIONAL
WALL PANEL
250MM. THICK
PRECAST INTEGRATION
SAVING USING
XPANEL TECH

WEIGHT (TONS) 4.03 2.25 44% REDUCTION IN WEIGHT

T O T A L C O N C R E T E ( M 3) 1.61 0.9 44% REDUCTION

STEEL IN PANEL (KG) 42.5

ADDITIONAL STEEL (KG) 119.91 13

T O T A L S T E E L R A T I O ( K G / M 3) 74.5 61.3 18% REDUCTION / M3

T O T A L S T E E L R A T I O ( K G / M 2) 24.08 11.14

54% REDUCTION IN STEEL

TOTAL STEEL (KG) 119.91 55.15
FOR WALL PANEL

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XPRECAST TECH BY IMZ HOLDING
 XPrecast material savings
vs. Traditional Precast

LOADBEARING PERCENTAGE
XPRECAST
TRADITIONAL
INTERNAL WALL
150MM. THICK
PRECAST INTEGRATION
SAVING USING
XPANEL TECH

WEIGHT (TONS) 2.97 2.25 24% REDUCTION IN WEIGHT

T O T A L C O N C R E T E ( M 3) 1.19 0.9 24% REDUCTION

STEEL IN PANEL (KG) 46.74

ADDITIONAL STEEL (KG) 99.49 13

T O T A L S T E E L R A T I O ( K G / M 3) 83.6 66.4 21% REDUCTION

T O T A L S T E E L R A T I O ( K G / M 2) 16.99 8.57

TOTAL STEEL (KG) 118.39 59.74 50% REDUCTION IN WALL PANEL

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XPRECAST TECH BY IMZ HOLDING
 Productivity of XPrecast system

ACTIVITIES XPRECAST TECHNOLOGY

REBAR HRS. 5

MEP HRS. 1

CASTING HRS. 1

CRANE HRS. 0

MANUAL LIFTING HRS. 0.5

DEMOULDING HRS. 0.5

TOTAL MAN HOURS PER M 3

8.0 HRS.

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production process
of XPrecast panel integration

PRODUCTION PROCESS
OF XPRECAST PANEL INTEGRATION

STEP 1:
XPrecast panels are delivered to precast factory with all required cut-
outs for windows and doors, including reinforcement U-mesh and flat
mesh, ready to be assembled in the factory. By providing ready made
XPrecast panels reduces the manpower hours required for fixing steel
cages by nearly 75%. The overall reduction in steel incident/m3 due to
the use of XPrecast 3D panel technology is a further direct saving on the
steel material cost.

STEP 2:
Precast steel fixers put the panels together, do the required splicing and
fix the XPrecast panels together with binding wire prior to insertion in
mould.

STEP 3:
MEP subcontractor can fix all required MEP items in the panel prior
to insertion in the mould. This further save time if there is a delay in
demoulding the previously casted panels in the mould. Once MEP is
completed, the precaster can manually lift the panel for insertion in
the mould. No requirement for overhead cranes, as the panel weight is
drastically reduce due to the XPrecast panel.

STEP 4:
Precast production team cast one layer of concrete in the mould after
which the completed XPrecast panel can be inserted in the mould on
top of the casted layer of concrete. Ensure concrete is properly binding
between the EPS and galvanised steel mesh.

STEP 5:
Once step 4 is completed, final layer of concrete can be poured into the
mould ensuring final precast panel ready for curing and finishing.

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 how the system
works
PLAY VIDEO

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XPRECAST TECH BY IMZ HOLDING

TECHNICAL SPECS.
XPRECAST SYSTEM
The XPrecast System represents an advancement in Xpanel technology, specifically
tailored for the Precast industry. This system comprises a set of Expanded Polystyrene
(EPS) panels, each side reinforced with a welded wire mesh made from high-strength
galvanized steel wires. These wires are interconnected using diagonally placed,
electrically welded galvanized steel connectors, ensuring robustness and durability.
The panels are manufactured using a fully automated welding line that precisely
assembles three key components: the welded mesh, truss spacer wires, and an
insulation core made of polystyrene. This advanced manufacturing process ensures
the production of panels with the highest level of dimensional accuracy. The strength
and rigidity of each panel are derived from diagonal spacer wires, which are welded to
the welded wire fabric on both sides. This construction mimics the behavior of a truss,
resulting in a structure that is exceptionally rigid and capable of providing adequate
shear transfer for composite action.
The galvanized steel wires of the panel complies with ASTM A185 standards, ensuring it
meets specific criteria for strength and durability. Additionally, the diagonal truss wires
and the wires used in the welded wire fabric are manufactured in accordance with
ASTM A82 standards, affirming their quality and reliability.
typical transversal and longitudinal cross section panel
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XPRECAST TECH BY IMZ HOLDING
how the system works
The panel’s insulation core is made of Expanded Polystyrene (EPS), which
is a modified, auto-extinguishable material meeting the requirements of
ASTM C578. This type of EPS offers a range of densities, approximately from
12 to 20 kg/m³, allowing for flexibility in application based on structural and
insulation needs.
The panels are available in EPS thicknesses ranging from 30 to 200 mm
and concrete layers starting at 50 mm, with an standard galvanized wire
gauges 4.0 mm forming a 100x100 mm welded wire mesh. The quantity
of diagonal wires, crucial for achieving the required shear strength, is 22
wires per square meter diameter 4.0 mm.
The dimensions of the panels are custom-made for each project,
ensuring a perfect fit for the specific requirements and architectural
needs.
3d view prefabricated panel
 how the system works

LIST OF SYSTEM
MATERIALS APPLICATIONS
Currently XPrecast System have mainly the following building applications:
ELECTROWELDED GALVANIZED STEEL MESH
• External insulated load bearing precast walls.
Fabric mesh is made of galvanized steel wires with diameter of 4 mm and complies with ASTM
A82 and ASTM A185. • Internal load bearing precast walls.
• Non load bearing precast walls.
The welded-wire fabric has a minimum yield stress of 500 MPa.
• Precast slabs.
The reinforcement grid is 100 x 100 mm. The geometry of the resulting meshes is 1.320 mm (100
mm will protrude on each side of the panel, on opposite sides, for the connection of adjacent • Claddings for residencial buildings.
panels) with variable length according to the required panel length. Additional reinforcement
• Claddings for industrial buildings up to 12 m.
mesh with similar specifications is supplied as part of the kit:
• Light weight modular precast units designed for easy transport, suitable
• FLAT MESH. Panel joints and corners of openings are reinforced with strips and sheets of for uses like portable cabins or security guard rooms.
welded fabric that are part of the kit to ensure continuity on the sides of the panel without
overlapping and cracking bars made by flat meshes sheet at 45º are used.. • Tilt-wall construction.
• U-SHAPED MESH. To reinforce the edge of the walls, customized U-shaped mesh is • Retaining walls.
supplied. • Civil works elements.
• Ornament elements for facades such as pergolas or curved shapes.
GALVANIZED STEEL CONNECTORS
The steel connectors are made of galvanised steel wires with diameter of 4 mm, and complies
with ASTM A82 with a minimum yield stress of 500 MPa.

EXPANDED POLYSTYRENE (EPS)

The panel’s insulation core is made of Expanded Polystyrene (EPS), which is a modified, auto-
extinguishable material meeting the requirements of ASTM C578. This type of EPS offers a range
of densities, approximately from 12 to 20 kg/m³.
Thickness of the EPS board shall be according to structural and thermal design.

XTOOL SPACERS
XPrecast Systems are equipped with custom-designed spacers, specifically tailored for Precast
solutions. These spacers are integral to the panel, ensuring the EPS core remains precisely
centered within the 3D truss structure throughout the concreting process.

CONCRETE
The concrete used in Xprecast must align with the specific requirements of the project. Its mix
design should account for a maximum aggregate size of 10 mm and target a slump test result
of 180 mm to ensure optimal consistency and performance.

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documentation

THE SYSTEM

COMMERCIAL DOCS

TECHNICAL DOCS

LINKEDIN CHANNEL

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XPRECAST TECH BY IMZ HOLDING
www.imz-holding.com