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Highly Automated Precast Plant Sets New Standards

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Highly Automated Precast Plant Sets New Standards 06b-Fertigteile_256-323_en_Layout 1 07.03.13 13:38 Seite 270 PRECAST CONCRETE 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 precast concrete 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 cement 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- concretes 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 formwork 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. 270 CPI – Concrete Plant International – 2 | 2013 www.cpi-worldwide.com 06b-Fertigteile_256-323_en_Layout 1 07.03.13 13:38 Seite 271 PRECAST CONCRETE ELEMENTS Visit us at Booth B1.142 Motorway Munich Feldkirc April 15 – 21 A94 P Nord n P N524 N624 N724 N832 N831 N932 0 nche 7 ü 3 M Nord 2 9 N523 N623 N723 N830 N829 9 Motorway etxi N N423N423 N TAXITAXI TAXI 8 München-Riem 5 2 Entrance open-air 2 A 9 9 N N522 N622 N722 N828 N827 N n 3 area north/west 6 Entrance open-air 2 Forwarding offices/ DD 1 1 2 9 d 9 N521 N621 N721 N826 N825 N Customs N N1024 e N area north/east 1 r 4 1 2 2 1 9 N418N418 9 1 N520 N620 N720 N824 N823 N 7 N 20 N1022 P 21 N919 N1020 N1020 N 19 2 o N519 2 1 N619 N822 N821 9 1 P Service 17a 1 i 18 N 6 Nord companies North TAXI n N820 N819 N719 N t North 920 17 N N1019 N1017 N718 N818 N817 1 15a 0 y N 1 e F6 71 8 tor t 16 7 N1018 lti-s Wes 417 617 N918 rk N816 N1016 Mu a 15 N r p 516 616 N916 9 F7 N815 1 ca 5 13a N91 n 515 615 715 4 e P F8 N1015 ab 14 g r 514 614 714 F9 N1115 11a ll 814 Hü North-t C 1 C 2C 3C 4 13 F10 F11 F12 F13 m Tower Wes 813a A F 613 713 813 12 11 512 612 O A 712 812 812a m a l M 711 811 1 essesee 1 o 8 a 710a f- 0 810 1 ICM B 0 710 8 a P 709 B 1 B 2 B 3 B 4 B 5 B 6 9 TAXI 809 0 alm 8 708 a 808 8 708 0 807 8 e West Atrium Atrium Am - East Messe- Stra turm A Park & m Ride car M Adminis- A 1 A 2 A 3 A 4 A 5 A 6 ß park e tration ssesee Service building e companies East P 1 2 3 4 5 6 7 8 9 10 Willy-Brandt-Allee Et i h 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. Free CPI- Samsonite trolley! 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.
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