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Constructing the new concrete productionfacility was absolutely essential. In the next12 to 15 years, a comprehensive develop-ment programme, concerning the waterinfrastructure in particular, will be imple-mented for all towns without exception inAzerbaijan. Besides manufacturing pipes,Star CP also supplies kerbstones and con-crete elements, such as paving blocks, man-ufactured using the vibro-compactionprocess. The production facility’s total areameasures 12 ha and the operational area11,000 m². Each year, 120,000 –140,000 m reinforced steel pipes will beproduced plus 500,000 m² concrete slabs.

Strong growth in Azerbaijan

The industrial history of Azerbaijan beginsin the early middle ages with the extractionof mineral oil on the Absheron peninsula.Due to its rich mineral oil resources,Azerbaijan took on an important politicaland economic role after proclaiming itsindependence in 1991 on the Eurasian con-tinent. The country has successfully over-come the difficult transformation time duringthe nineties of last century and has regis-

tered a continual economic upswing sincethen. GDP growth in the Republic ofAzerbaijan was especially high (averaging24.2% per year) between 2005 and2008. The country boasted the highest eco-nomic growth in the world during that time.Azerbaijan contributes approximately twothirds to the total gross domestic product ofall Caucasus countries. The country is quiterightly spoken of as the economic drivingforce in the region. Azerbaijan’s ascenden-cy is a result of its economically liberal pol-itics and cosmopolitan outlook. Specialattention is paid to economic cooperationwith the EU countries with a view to utilisingtheir innovative technologies for their owncountry’s economic development. The main-stay of this policy is very rapid growth in theconstruction sector, which occupies a spe-cial position within the context of the econ-omy’s overall modernisation. An extensiveprogramme for constructing state-of-the-artconstruction material production facilitieswas carried through by order of theAzerbaijani President, and financed withfavourable state-sector loans. A loan of 70million manats was granted for the con-struction of 18 facilities with a total value of

186 million manats (1 manat = approx.US$ 0.95). 14 new facilities are already inoperation producing construction materialsof the highest quality with the assistance ofmachines from leading European manufac-turers.

Construction work begins

Sumgait, the third largest town in theRepublic of Azerbaijan, was selected assite for the new facility. Sumgait had expe-rienced its heyday as an important industri-al hub quite long ago but is slowly regain-ing its renown as the major industrial centrein the Caucasus. In the vicinity of Star CP,new production sites are being set up formanufacturing carbamide, superphosphateand chemical additives for mineral oil prod-ucts. The crown jewel of the Republic ofAzerbaijan – the great multi-purposeSumgait technological park – is locatedonly a short distance away. The Ministry forEconomic Development had made a build-ing site “of national standing” available forconstructing this Star CP production facilityby the coast of the Caspian Sea on thepremises of a former chemical factory. Old

Concrete giant in the Caucasus

Prinzing-Pfeiffer GmbH, 89143 Blaubeuren, Germany

One of the biggest and most ultra-modern concrete production facilities in East Europe was commissioned in Azerbaijan at the beginning of2015. Even President Ilham Aliyev was guest at the opening ceremony in Sumgait for the inauguration of the new StarConcreteProduction(Star CP) production site. The facility had been constructed on behalf of Azersu, the state-owned stock company, whose specialists wereresponsible for technical planning and operational performance. Star CP (formerly Azkontakt) and Prinzing-Pfeiffer (Schlosser-Pfeiffer GmbHat the time of signing the contract) were able to implement this planning successfully. Star CP will not only supply Azersu with reinforcedprecast concrete components (pipes, manhole rings, manhole bases, cones) but will as well supply private companies who are engaged inconstructing or reconstructing the water supply and waste water disposal systems in Baku, Sumgait and other towns of Azerbaijan.

Finished reinforced concrete pipes before delivery to customers The new production facility halls were erected in a very short timeaccording to specifications from Prinzing-Pfeiffer

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production structures and the remains of theprevious infrastructure still stood on the ter-rain. Some buildings were torn down andthe building site newly developed.Renovating these premises and preparingfor the new construction took much timeand work. Besides production halls, officeblocks were constructed with pleasantrecreational and social rooms including acanteen for 150 persons. Right from the out-set, the company’s management devoted agreat deal of attention to the interests anddesires of employees. Everything was doneso that employees would like to come towork, would feel good and be suppliedwith all they need. The new productionfacility was constructed in a very short time;it took only one year and eight months.Construction work began in the spring of2013; the commissioning took place inJanuary 2015.

The director general, Ilham Hajiyev, playeda special role in constructing the facility. Hisvisionary capabilities launched the birth ofthis production site, long before the firstplans and calculations had been carriedout whilst many still held the ultra-modernfacility for Utopia. Where others only saw arun-down, ruined site, Hajiyev couldalready visualise the biggest concrete fac-tory in Eastern Europe. Even now that thefacility has been completed, there are stillsome who think it a fata morgana.

Machine selection process

In checking through all potential suppliers,the spotlight fell in particular on one of theleading manufacturers of concrete pipemachines in the world – Prinzing-PfeifferGmbH from Blaubeuren, Germany. In thisrespect, the Star CP engineers gathered an

enormous amount of information about itsmachines, concrete products and the com-pany itself.

Mr Ilham Hajiyev, General Director of theproduction facility says: “One importantargument in favour of Prinzing-Pfeiffer is itscountry of origin. We all know very wellthat German quality is ranked among thebest in the world. There is a tradition inGermany of making robust and very reli-able machines. This goes for cars, machinetools and all other systems.”

“In our selection, consideration was not justgiven to the excellent standing of Germanengineering and information aboutPrinzing-Pfeiffer but to the opinion of col-leagues as well. We had asked eight verylarge concrete pipe manufacturers whatmachines they were operating. The answer

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The first production halls standing only 10 weeks after beginningconstruction

Prinzing-Pfeiffer Variant 3600/2500 for concrete pipes up to a3,600 mm and lengths up to 3.0 m

Mr Ilham Hajiyev, general director "Star CP" and Mr AlexanderProbst, regional manager Prinzing-Pfeiffer

The future "Star CP" production facility terrain during the first siteinspection

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was that six out of eight companies hadmachines from Prinzing-Pfeiffer in opera-tion. Conversations with colleagues fromRussia and Saudi Arabia – both totally dif-ferent countries – underscored the high rep-utation of Prinzing-Pfeiffer machines. Today,I can say from our own experience that ourexpectations have even been exceeded.More than six months after commissioningthe facility, we are still very happy to havemade the right decision at that time,” saysIlham Hajiyev.

Facing the future

The Star CP production facility has beenequipped with state-of-the-art technologyfrom Prinzing‑Pfeiffer and many other west-ern companies. Besides the actual produc-tion system, the entire peripheral equip-ment, such as e.g. trucks, lifts, forklifts andcranes, has been sourced in Germany. Concrete mixing is carried on with the aidof two mixing systems from Prinzing‑Pfeiffer.They are equipped with weighing and dos-ing devices for both liquid and dry admix-tures and can cope with up to three types ofcement simultaneously. Although the mixershave been set up for optimum operationwith the current needs, they still have sub-stantial productivity reserves for any subse-quent increase in output. Retrofitting theconcrete mixing machine with additionaloptions for enlarging processing capabili-ties is also possible. Such options includeadditional automation equipment such as,for example, robots and dosing systems formetal fibres, admixtures or aggregates inmanufacturing reinforced concrete ele-ments with special characteristics.

A total of eight moulding stations were built.Steel reinforced concrete pipes – including

a polyethylene inner lining (inliner) if need-ed – can be manufactured with an internaldiameter of 300 mm up to 2,500 mm ateach station. One station can even managepipes with diameters up to 3,600 mm andup to 3,000 mm long. A Variant 1500 isemployed for producing manhole rings,manhole bases and cones. This systemmakes it possible to manufacture the above-named products with inner diameters up to1,500 mm and heights up to 1,000 mm.Depending on the engineering assignment,manhole rings with a height of 300 or 600mm can be produced alongside rings andcones measuring 1,000 mm in length. TheModulant 765 system can produce seatingrings with heights from 40 to 250 mm thatare needed for positioning covers. Metalreinforcement cages can be manufacturedin any shape or size from 300 mm up to3,000 mm with the aid of two large weld-ing machines.

The gantry turning units with load-bearingcapacities of up to 15 and 25 tonnes plustransport cars make for well thought-outproduction logistics. Their own fleet of vehi-cles made by Spezialtechnik consisting of10 automated tippers, 10 concrete mixers,2 stacker trucks and 4 trolley cars of differ-ing tonnage guarantee that all productsmanufactured will be delivered on time.

Alexander Probst, the regional manager(Eastern Europe) of Prinzing-Pfeiffer GmbH,comments: “Specific technical requirementsdetermined the choice and make-up of thesystems. A wide range of products wasspecified as one particular objective. TheUniversal machines are well suited to this.Great importance was attached to beingeasily able to expand the facility even atthe project stage for the system. This applies

to both the existing machines and to settingup new ones. To take but one example, anadditional pit with a ready-made founda-tion and all the connections needed wasprepared but the automated high-perfor-mance machine (200 rings per shift) fore-seen for it will be installed at a later point intime. One enormous advantage for Star CPwas being able to redesign the productionfacility from scratch without having to giveheed to any existing machines or plant. Thismeans that there were no limitations set tooptimum machine and automation engi-neering or perfect production logistics fromloading silos to removing the finished com-ponent.

All machines are computer controlled andautomated, thereby both reducing humanerror to a minimum whilst also at the sametime enhancing product quality. The auto-mated processes include: producing theconcrete mix, feeding mixes into themachines, controlling the compactionprocesses and the vibration table. Machineoperators have only to manage the systemand make corrections to the workingprocess if necessary.”

“We greatly appreciate our partnerPrinzing-Pfeiffer not just as a manufacturerand supplier of first-class machines but alsoas a highly qualified engineering serviceprovider. All drawings for the system includ-ing those for the machine foundations wereprepared by the company’s specialists.They supported us tirelessly in all workprocesses, no matter what they concerned:manufacturing reinforcement cages orwelding polyethylene pipes. For us, as cus-tomers, it is very convenient to have to worktogether with only one company andsource the entire equipment from one sup-

Grab for turning pipes with products up to 15 tonnes in weight Prinzing-Pfeiffer Variant 2500 during production

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Pr

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plier. This supplier is both very skilful andvery reliable as well. Prinzing-Pfeifferemployees were able to answer all ourquestions, even those we had not initiallythought of. Although the deadlines werevery tight, everything was completed ontime, very conscientiously and in accor-dance with all our wishes. The Germanproject manager, Mr Alexander Probst,was not just continually well informed aboutall matters; he was also often in Sumgait tosolve problems on site. It is largely due tohis work that the partnership relationsbetween us and Prinzing-Pfeiffer are sogood and that problems in understandingnever cropped up in communication. Ourskilled employees learnt how to handlethese modern German machines veryquickly, which was very helpful for their suc-cessful integration into our production ide-ology”, comments General DirectorHajiyev.

Customer image – highest quality demanded

Star CP customers fall into one of two cate-gories: on the one hand, Azersu the gov-ernment-owned stock company and, on theother, various participants on the market.Pipes with very large diameters are particu-larly interesting for Azersu. Private compa-nies buy pipes with 800 and 1,000 mmdiameters, i.e. mainly pipes, manholebases, rings and cones. The production ofkerbstones, paving blocks and other small-er concrete elements is mostly aimed at pri-vate companies. Nonetheless, even theproducts destined for other market playersare monitored by Azersu and their qualitychecked before they can be utilised forprojects. In addition, products employed inwater supply facilities and sewer systemshave to undergo stringent examination by

the Ministry of Emergency Situations. This isalso why solely products of the highestquality level are in demand. In cases con-cerning town infrastructure, manufacturersare obliged to respect and to fulfil all stan-dards with essential components, such aspipes, manholes, etc., no matter whetherthe buyer is a private customer or the state-owned company.

Ilham Hajiyev, general director of the StarCP production facility, remarks: “Goodquality — is an indispensable prerequisitefor working successfully on the market.Good quality is thus also the main priorityfor all employees at the Star CP productionfacility. Assuring the quality of our workbegins by checking the raw materials andaccessories (aggregates, cement, addi-tives) and does not even end in the precastcomponent storage area although thechain of technological processes may havebeen completed. Specialists from our facili-ty and representatives of other organisa-tions and state structures (e.g. employees ofthe Ministry of Emergency Situations andscientific institutions) test Star CP products“in-situ” - where they are used. Thisexcludes practically every possibility of sup-plying defective products. A whole range oforganisational and technical measureshave been put in place for quality assur-ance. All employees down the line from hallmanagers to shift foremen assume greatresponsibility for quality assurance. Theemployees at the facility’s laboratory makea major contribution to this. Cooperationwith the Republic’s leading scientific institu-tions also plays an important role in qualityassurance and in answering incidentalquestions. Employees at these institutions, inthe context of their research work or elseworking continually with the company, takesamples of the products “under field condi-

tions”, subject them to testing and thenmake their reports available to the facilitymanagement.

State-of-the-art equipment – new opportunities, cleaner production

A wide range of products, cost reductions,quality assurance, enhancement of produc-tivity and operational performance are fea-tures of state-of-the-art equipment from theworld’s best manufacturers. At the sametime, these features generate savings onenergy, reduce environmental pollution andcreate user-friendly and safe working con-ditions. More than 200 new jobs were cre-ated by Star CP. This is sustainable, long-term support for the region.

Successfully expanding and opening upforeign markets are realistic goals for thefuture. Its unique technical equipment andproduction volumes allow Star CP to serveboth the inland market of the Republic ofAzerbaijan and to supply its products to theneighbouring countries – Iran, Kazakhstan,Uzbekistan, Turkmenistan, Georgia andsouthern areas of the Russian Federation.Demand for these products is very great,since local manufacturers can neither deliv-er the product range desired nor therequired product quality. They include, forexample, the pipes with polyethylene jack-ets or pipes for micro-tunnels with diametersbetween 2,000 – 3,000 mm.Great attention is paid to keeping the envi-ronmental laws of the Republic ofAzerbaijan. Industrial waste water iscleaned very thoroughly, enabling part ofthe waste materials to be recycled. Allcement silos are equipped with powerful fil-ters; this is why the surroundings are not pol-luted with cement dust. The company alsofocuses strongly on personnel planning.

The hardened pipes are transported from the hall with a transportcarriage to the outdoor storage site

The "Star CP" show gardens for its concrete pipe and concrete manhole product range

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April 11th - 17 th Open-Air Ground FS 1307Hall B1/425

QUICKLY. EASILY. GRIPPING. www.probst-handling.co.uk

Probst AZ Betonwerk 210x103 RZ Bauma englisch.indd 1 29.02.16 10:14

Continuous training and ongoing education for employees of alldepartments is another stepping stone on Star CP’s path to success.

Star CP: Unique project – unparalleled experience

The Star CP production facility – in terms of its size, machine volumeand other parameters, still remains the biggest project thatPrinzing‑Pfeiffer GmbH has ever undertaken. There have been simi-lar projects but the possibilities and perspectives of this project arereally unparalleled. In Sumgait, a whole range of difficult technicalchallenges were successfully resolved, e.g.: manufacturing pipeswith built-in high-density polyethylene (HDPE) and maintaining max-imum output in manufacturing pipes of medium and large diametersfor differing loading levels. The organisation of all processes had tobe optimised progressively to be able to guarantee such perform-ance. This means that the concrete mixer, the equipment for feedingand spreading the concrete, the machines for producing reinforce-ment cages, the technology for fabricating precast components, theturning device, etc. – no link in the chain of operations was tooweak.

Mr Alexander Probst is of this opinion: “For our company, Prinzing-Pfeiffer GmbH — a company with more than 100 years’ experiencein working in many countries of the world – this project was a realchallenge. Working together with Azkontakt was very importantand extremely interesting for us. Now that this work has been com-pleted, Prinzing-Pfeiffer GmbH wants to thank their Azerbaijani col-leagues for their trust, for their all-round willingness to help andhopes that new projects can be carried out in the future.”

The concrete production facility in Sumgait is proof of the possibili-ties and perspectives as regards economic development in theRepublic of Azerbaijan and a statement of the country’s enormouspotential. It also gives an indication of the great success that can beachieved through modernising production infrastructure assisted bycutting-edge, innovative technologies and machines. �

CONCRETE PIPES AND MANHOLES

Finished manhole base components with formed inlets and outlets

FURTHER INFORMATION

Prinzing-Pfeiffer GmbHZum Weißen Jura 389143 Blaubeuren, GermanyT +49 7344 1720F +49 7344 17280info@prinzing-pfeiffer.de www.prinzing-pfeiffer.de

StarConcreteProductionBaku, Nizami rayonu,Oqtay Vәliyev — 1AT +994 (12) 570 14 19,T +994 (12) 570 04 49F +994 (12) 570 14 18offce@starbeton.az

Stand B1.127

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