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PRECAST ELEMENTS

FBW Fertigbau Wochner GmbH & Co. KG, 72358 Dormettingen, Germany Highly automated precast plant sets new standards

One of the most modern precast plants in Germany was put into operation at the start of 2011 at FBW (Fertigbau Wochner). FBW, a Vogel- Bau Group company, produces sophisticated elements at its site in Dormettingen with a largely fully automatic production facility. In addition to structural precast elements of all kinds, FBW’s products also include concrete walls made using the solid or sandwich construction method. The new plant is intended above all for the production of solid walls, sandwich elements and other flat concrete prod- ucts such as floor elements etc.

The initial project studies for the planning of Flexible mixing plant adapted to the rotary distributor is attached to every sec- the new plant by Prilhofer Consulting customer’s requirements ond mixer closure for discharging the con- began in 2007. The contracts were award- crete selectively into the concrete distributor ed to the plant manufacturers in mid-2010 A Liebherr mixing plant of the type or into a truck mixer or into the cleaning and commissioning took place in mid-2011. Kombimix was specially adapted to the cus- hopper of the recycling plant. The plant has been in full operation since to mer's requirements for the central supply Three silos with a total storage capacity of October 2011 and is capable of producing of concrete. The mixing plant is equipped 300 tonnes in 5 chambers are available for an area of around 85,000 m2 per year with with two ring pan mixers, a RIM 2.25-D and fillers. In addition to separate average part complexity, requiring only 3.5 with dual agitator system and a RIM 1.0-M white cement scales, the mixing plant has man-hours per cbm of precast concrete ele- with mono agitator system. These mechani- scales for microsilica slurry, colour slurry ments. Hence, the plant is considered a cal agitators achieve very high concrete and admixtures. trend-setter for the flexible production of qualities in a short mixing time. Short emp- Concrete residues resulting from the clean- solid and sandwich elements with regard to tying times are a further advantage of the ing of the mixing plant or the concrete dis- machines and efficiency. ring pan mixers. These mixers are particu- tributor are taken up by a Liebherr recycling larly well suited to the mixing of special plant type LRS 606 sunk directly under- with the addition of dye or addi- neath the mixing plant. This recycling unit tions. separates grey and coloured residual water The mixing plant possesses a concrete in- in two agitator tanks and is capable of fil- line silo as an active store for 15 different tering out Liapor residues. The entire con- aggregates with a total stock of 540 m³. crete mixing plant is integrated completely The in-silo is filled by a belt bucket convey- into the concrete building and is thus heat- or with a spur belt and a mobile, reversible able and fully suitable for use in winter. rotary distributor belt. All chambers of the in-line silo dose via 10 closures and 5 belts Master computer and control technology onto a weigh belt. Further special granula- tions can be transferred directly onto the The brain of the complex plant is the weigh belt via two interchangeable steel UniCAM master computer from Unitechnik. The new plant at FBW Fertigbau Wochner, tanks. Each ring pan mixer has an after-silo It manages the orders, fills the pallets, coor- which belongs to the Vogel-Bau Group, has which can take up a batch and discharge it dinates and visualises the production, gen- been in full operation since October 2011 directly into the concrete distributor. A erates the NC data for the robot,

Two ring pan mixers from Liebherr achieve high concrete qualities in Rotary distributors under the mixers convey the concrete selectively a short mixing time to the concrete distributor, into a truck mixer or into the cleaning hopper of the recycling unit.

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PRECAST CONCRETE ELEMENTS Visit us at Booth B1.142

Motorway Munich Feldkirc April 15 – 21 A94

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A total of 40 shuttering pallets measuring Persistent contamination is removed by 14.00 x 4.60 m are used at FBW an additional cleaning unit on the pallet cleaner

controls the laser projectors, manages the has a thickness of 10 mm and is finely and hardening chambers and ensures correct evenly aligned and polished several times stack formation. In addition it forms the for the achievement of perfect concrete sur- interface to the Betsy ERP system and to the faces. Mounting holes enable the mounting DICAD CAD workstations in the technical of fixed edge shuttering. The pallet is office. Information can be retrieved by the designed for a 40-tonne payload, which employees not only from the control centre, defines a new standard. but also via the network from office work- In the longitudinal direction the pallets stations. move by means of a frequency-controlled Special CPI subscription offers! * The time required for manual work steps friction wheel conveyor system over roller varies a great deal due to the large variety blocks and in the transverse direction by of individual products, which are produced means of cross-lifting truck pairs between Free concrete pen on five production lines. In order to prevent the individual work stations. Vollert sup- pack! bottlenecks and to achieve optimum plant plied the cross-lifting trucks with an intelli- + CPI back performance, the system operates with gent synchronisation system in which an work schedules. The order in which the indi- absolute value encoder controls the con- vidual stations of the variable plant layout stant regulation of the truck feed. As soon should be driven to is defined for different as a deviation is measured, the control sys- product types. At present the plant is oper- tem regulates the speeds of the cross-lifting ating with 19 different work schedules. trucks, each of which transports one shut- 1 year subscription The complete plant is equipped with state- tering pallet to the next work process. of-the-art safety-orientated control technolo- gy. Touchscreen operating terminals in the Pallet cleaning plant provide for intuitive operation and fast error analysis. A Beckhoff controller is used For the cleaning of the pallets Wecken- for controlling the robot. mann has installed a stationary pallet cleaner that has an additional cleaning unit 2 year subscription Production sequence for the removal of persistent contamination, e.g. facing paint. If there are fixed super- A total of 40 shuttering pallets from structures on the pallet, the cleaner is lifted Weckenmann measuring 14.00 x 4.60 m by means of electric motors for free pas- with a maximum production width of 4.20 m sage. Fine dust on the pallets is vacuumed are used at FBW. The shuttering sheeting off automatically.

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International trade journals for the concrete industry Published in 13 different language The M-Basis/M-Top shuttering system before and after assembly. The transponders are located in a protected place on the faces of the profiles editions

*Special CPI subscription offers are valid www.cpi-worldwide.com CPI – Concrete Plant International – 2 | 2013 only at bauma at booth B1.142. 06b-Fertigteile_256-323_en_Layout 1 07.03.13 13:38 Seite 272

PRECAST CONCRETE ELEMENTS

The three post-processing stations are equipped with laser projection units from Unitechnik

M-Basis/M-Top shuttering system

The Twin-Z shuttering robot makes extremely fast cycle times The M-Basis/M-Top system from Weckenmann consists of a base possible when positioning the shuttering on the steel pallets profile with integrated magnets onto which one or more profiles of various heights, but the same length, can be simply placed. The pro- files can be locked to the base profile and the switchability of the magnets can be forwarded to the top side of the shuttering via a coupling element. This shuttering system was used on a large scale for the first time at FBW. With 10 different base profiles and 2 different top elements, up to 27 different shuttering heights can be assembled within the range of 100 - 500 mm. The shutterings were built in 4 lengths from 750 mm to 3,000 mm. During the realisation the question quickly arose of how the individ- ual assembled elements can be reliably identified in automatic use in a robot environment. The previous method using sensors that sensed the length and the height of the profile no longer worked here, because it is quite possible for a shuttering height to be realised by different combinations of individual shuttering profiles. The Weckenmann engineers therefore decided to use RFID techno l- ogy. For the clear identification of the shuttering parts they are equipped on both faces with RFID chips. A RFID system consists of a transponder, which is located in the shut- tering and contains an identifying code. All RFIDs of the assembled shuttering are read at an identification station and the characteris- In order not to hinder the pallet cycle, this procedure takes place tics of the combination shuttering are derived from this. The control at a second working level above the circulating system. technology from Unitechnik manages this universal shuttering system and thus regards assembled shutterings as a single shuttering.

Information that serves the control of production and the organisa- tion of maintenance can additionally be written to the transponder within the production process if need be. In this way it is possible, for example, to determine the number of circulations of an individual shuttering profile and to send it for checking or overhaul after a cer- tain number of uses.

Shuttering robot

The Twin-Z robot from Weckenmann has direct access to the shut- tering magazine with about 150 magazine compartments, which can take up to 20 shutters on top of one another depending on the shuttering height. The positions of the individual posts are adjustable, which permits re-allocation of the magazine at all times. The robot fetches the very heavy shuttering profiles, which can be up to 500 mm high and 3000 mm long due to the combination pos- sibilities described above, and places them quickly and precisely on the pallet. The work area measures 17.5 x 9.5 m. Due to the double To this end hydraulic scissor-lift trucks lift up the shuttering pallets Z-axe, which grips and switches the shutterings directly by the two at a total of three positions to the individual post-processing integrated magnet units, the cycle time is only about 60 % that of stations at a lifting height of 2.80 m. conventional robot technology.

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The pallets are subsequently taken to three independent parallel The concrete distributor is designed as a swap bucket system, production lines for the manual placement of the reinforcement each bucket having a capacity of 3 m3 and the installation of the insulation

Manual additional shuttering procedure Vollert developed a solution for this that ing process. Weckenmann supplied three at a raised working level makes it possible to decouple individual pal- tool trolleys for the manual post-processing lets from the circulation.To this end hydraulic stations. Each trolley is equipped with a After the shuttering profiles have been posi- scissor-lift trucks take the shuttering pallets glue gun and a manual oiling device, for tioned by the robot for the outline of the later out of the circulation in a fully automatic which the form oil is drawn from a central precast concrete element, the pallet is taken work process and lift them up at a total of form oil tank. The three post-processing sta- for the manual placement of further special three positions to the individual post-pro- tions are equipped with laser projection and built-in components, e.g. electrical wall cessing stations. As soon as the lifting units from Unitechnik, which provide for sockets or timber frames. In order not to hin- height of 2.80 m is reached, the pre- bright and sharp lines, but are designed der the pallet cycle, this procedure takes installed extendable protective railings on such that working without safety glasses is place at a second working level above the the upper level are lowered and the pallet possible. The laser projectors are controlled circulating system. The engineers from is freely accessible for the manual shutter- directly by the UniCAM master computer.

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IWLAN antenna on the concrete distributor The concrete is compacted after the concreting procedure by means of a combined shaking/vibrating station

That allows maximum control with regard to lation cycle and lower plant productivity. As ‘Industrial Wireless LAN’, or IWLAN for the information to be projected. The laser soon as the work procedure is completed short, from Unitechnik was used for the first projection is used mainly for the positioning here, the prepared pallets are taken to the time in the area of the concrete distributor. of electrical outlet boxes and load anchors. concreting station. The concept with two buckets on a cross- Once the pallet is released again, the fall beam serving two places requires a com- protector drives back to its initial position Concrete distributor with data munication system with many degrees of and the pallets are lowered again and put communication via IWLAN freedom that nevertheless meets the require- back into the actual circulation. ments for real-time communication and The concrete distributor was designed by makes safety functions possible. The Installation of the reinforcement on Weckenmann as a swap bucket system for IWLAN system from Siemens meets these three parallel processing sections grey and facing concrete, each of the two requirements. concreting units having a capacity of 3 m3, After being lowered, the pallets proceed with spiked roller dosing for the processing Weckenmann also supplied a floor-driving further to three independent parallel pro- of different . smoothing trowel, which can switch duction lines, in each case to the next work- The swap buckets take up the concrete separate- between the two concreting stations by ing position. There, the reinforcement, the ly from the various mixers. To this end they means of a cross-drive and which is likewise insulation and the remaining built-in compo- drive out of the bridge extending in the lon- equipped with a height-adjustable work nents are installed; further laser projection gitudinal direction of the pallets onto two platform. This allows the operators to carry units from Unitechnik are attached above branch lines, on which the cleaning and out any necessary work on the already con- two of the stations for the placement of built- maintenance also takes place. The concrete creted slab without having to directly step in components. Distribution to three pro- containers can be moved hydraulically by on it, for example to carry out supportive cessing sections ensures that, for example, 1000 mm in a vertical direction, so that compaction using an internal vibrator for special parts with particularly time-consum- they can be adapted optimally to the dif- complicated element geometries. ing work processes do not hinder the circu- ferent component heights.

A floor-guided storage and retrieval device (SRM) with a wing To this end the rack doors are opened first by a segment door open- traverse places the pallets into storage in the hardening chamber er and the pallets are then placed into or removed from the desired and removes them again fully automatically. pallet compartment via friction wheels and a gear rack pusher

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PRECAST CONCRETE ELEMENTS

At the smoothing station the elements are post-treated several The tilting station from Vollert is designed for a maximum load of 50 times if necessary, depending on the required surface quality t and enables the vertical lifting off of the concrete components over different angles of tilt

Compaction stations for different ferently, depending on the weight. This cy vibration station. For this the vibration precast concrete elements makes an optimum, circular shaking move- energy of the eight external vibrators is ment with low noise possible. The desired transmitted to the pallet via the roller The concrete is compacted after the con- compaction can thereby be precisely blocks. creting procedure by means of a combined adjusted. Considerably stiffer concrete can For solid walls with upturn beams or with shaking/vibrating station from Vollert. also be processed here. By lowering the installed insulation, the concreting unit has Optimum surface and edge quality is thus water-cement mixing ratio while maintain- a further vibrating station which is integrat- achieved. The low-frequency vibrating ing a constant early concrete rigidity, the ed into the parallel working line. The frame movement is generated by four unbalanced cement proportion can be reduced by of the vibrating station lifts the shuttering drives, thus compacting the concrete. The about 10 %. The concrete is additionally pallet pneumatically out of the circulation unbalanced masses are synchronised dif- compacted by an integrated, high-frequen- for this. As a result, the effect of the 12

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The loading solution supplied by Vollert allows the deposition frames At the shuttering cleaning station the shuttering is cleaned, oiled and to be taken up by a run-off truck and then transported further to the subsequently fed back to the magazine of the shuttering robot in outdoor area accordance with its identification

external vibrators is also directed toward keep the running and maintenance costs platform and is separated by fully automat- the centre of the pallet and provides for the low, protection against rope breakage was ic roller shutters. At the smoothing station, necessary, high frequency compaction of increased for the SRM. By means of the which was supplied by Weckenmann, the the concrete. The vibrating station was fitted appropriate dimensioning of guide rollers, concrete surfaces are mechanically with an additional vibration decoupler in rope drums and ropes as well as high-qual- smoothed both with the disk and with trow- order to reduce noise emissions. ity materials, the life span is extended by up els at three stations arranged in parallel. All to five years. Vollert uses rope suspension drive movements and the speed of the Hardening chamber with storage and gear here with a spring system that absorbs smoothing tool are infinitely adjustable via retrieval machine and smoothing station the developing tensile force in a spring radio. assembly, thus preventing rope breakage. The insulated hardening chamber which, A further special feature of the SRM is a The setting angle of the trowels can be like the storage and retrieval machine light barrier that measures the height of the adapted by electric motor to the respective (SRM), was supplied by Vollert, is heated incoming precast concrete element and concrete consistency. Depending on the and consists of four rack towers, each with stops the work step by means of an auto- required surface quality, the pallets are 12 pallet storage compartments arranged matic start/stop mechanism if the maximum taken one or more times to the hardening one above the other. The floor-guided SRM permitted overall height is exceeded, for chamber for pre-hardening between the with a wing traverse places the pallets into example in the case of protruding rein- smoothing procedures. storage in the hardening chamber and forcements or incorrectly attached built-in removes them again fully automatically. components. As soon as the final hardening time has To this end the rack doors are opened first After a hardening time of about three hours, been reached the pallet proceeds via a by a segment door opener and the pallets the concrete elements are first taken out of separate discharge compartment to the are then placed into or removed from the storage by the SRM and then transported demoulding procedure. The passage is desired pallet compartment via friction to the smoothing station on the opposite completely encapsulated so that no heat wheels and a gear rack pusher. In order to side, which is situated on an overhead work can escape from the hardening chamber.

For quality assurance a photo is automatically taken of each pallet before concreting using an industrial camera

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Tilting station for lifting off the precast takes them back to the approximately 1.5 FURTHER INFORMATION concrete elements/run-off truck metre lower transverse cycle conveyor, which is located in the robot work area. In order to achieve the desired production capacities, the engineers from Vollert Quality assurance is written FBW Fertigbau Wochner GmbH & Co. KG banked on optimum loading processes. in capital letters at FBW An der Bräunegrube 2, 72358 Dormettingen, Germany “The tilting station is designed for a maxi- T +49 7427 770, F +49 7427 77500 mum load of 50 t. Vertical lifting off can Particularly high importance is attached to [email protected], www.wochner.de take place at various angles of tilt, at an the subject of quality assurance in the entire inclination of 72° or 75°, or even at an plant at FBW. A photograph is taken of inclination of 80°, which is necessary in each pallet before concreting. To this end particular with special parts. The tilting sta- an industrial camera was attached by tion additionally has a hydraulically mov- Unitechnik at a height of 12 m above the able support beam designed to take the workstation. The triggering and the trans- Prilhofer Consulting weight of the precast concrete elements. In mission of the image file take place via the Christian Prilhofer Münchener Str. 1, 83395 Freilassing, Germany the case of pallets with no fixed edge shut- network. The UniCAM master computer T +49 8654 69080 F +49 8654 690840 tering, the support beam moves beyond the takes care of control and archiving. Using [email protected], www.prilhofer.com edge of the pallet, thus preventing the con- the picture the condition of the pallet before crete element from slipping during the tilting concreting can be reproduced in the case procedure”, explains Björn Brandt from of a complaint. In this way it is possible to Vollert. document whether all built-in components Deposition frames, on which the precast and reinforcement elements were integrat- Unitechnik Cieplik & Poppek AG Fritz-Kotz-Str. 14, Industriegebiet Bomig West concrete parts are initially placed, are ed and, to a certain degree, the dimension- 51674 Wiehl, Germany installed for the following loading process. al accuracy of the pallet can also be veri- T +49 2261 9870, F +49 2261 987510 Stand B1.129 These stand on deposition bolsters fied. [email protected], www.unitechnik.com equipped with a special track-guided super- A second quality assurance step was structure. This solution supplied by Vollert installed by Unitechnik before the lifting off enables the deposition frames to be taken of the elements. After the shuttering has up by a run-off truck with two cross-lifting been removed from the pallet, the pallet Vollert Anlagenbau GmbH trucks and subsequently to transport them drives through a measuring gate in order to Stadtseestr. 12, 74189 Weinsberg, Germany further to the outdoor area for loading. reach the tilting table. While driving T +49 7134 520, F +49 7134 52203 Stand B1.204 through the gate the elements on the pallet [email protected], www.vollert.de Transport and cleaning of the shuttering are measured three-dimensionally. The image of the produced element is now com- The shuttering is removed from the pallet by pared with the CAD data. means of a bracket crane and a safe trans- The graphic image of the elements is dis- Weckenmann Anlagentechnik GmbH & Co. KG port spreader bar and placed on a roller played to the employee on a monitor. Birkenstraße 1 conveyor about 30 m in length. The shutter- Edges that lie outside the tolerance are 72358 Dormettingen ing is transported on this conveyor through marked red. Hence, faulty elements are Germany the cleaner and oiler, supplied by recognised promptly and are not even T +49 7427 94930, F +49 7427 949329 Stand B1.219 Weckenmann, and subsequently identified delivered to the building site, which saves [email protected] by RFID readers. A lowering station then expensive complaint costs. ˾ www.weckenmann.com

Before the hardened elements are lifted off, the pallets pass through a measuring gate in which the dimensions of the finished elements are documented and checked by means of industrial lasers

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