Trade Journal for the Concrete Industry - Elematic, 37801 Akaa, … · 2012-12-22 · prestressed...
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CPI – Concrete Plant International – 6 | 2012 www.cpi-worldwide.com 136 PRECAST CONCRETE ELEMENTS With its 174 m in length, the modern hall structure has become the new showcase for Pauli Beton. Construction of the new hall and production line commenced in September 2011. View of the new production line for prestressed hollow-core slabs. The concrete mixing plant, in the background, with its 2.25 m³ planetary mixer for supplying the production line with concrete. Silos inside of the production hall for sand and aggregates ensure uniform moisture content when producing concrete. Michael von Ahlen, CPI worldwide, Germany The Pauli Beton precast concrete produc- tion facilities have been in existence since the 1950s and have their roots in the north- western part of Belgium. From the outset, the company’s core business has been the manufacture of concrete blocks and non- stressed reinforced wall and floor elements. The company has been headed by the sec- ond generation of the Pauli family since 2003 with four family members Steven, Griet, Jean-Marie and Bart sharing the firm’s management. Although the division of tasks is clearly defined, work is carried out “hand in hand”. The decision to expand the product range was made at the end of 2010. Elematic was chosen for the prestressed hollow core slab production line after an intensive search for a suitable business partner and quite a number of meetings for consulta- tions. “Elematic gave us the impression of being the most professional and the most down to earth at the same time. It wasn‘t just a mat- ter of their expert advice and the profes- sional support of their Finnish commission- ing team; our interpersonal contacts were also out of the ordinary,” explains Steven Pauli, who is responsible for purchasing and finance at Pauli Beton. Site visits to functioning facilities were a decisive factor in finally tipping the scales towards Elematic equipment. “During economically difficult times, a large investment carries a certain risk, and more especially so in an area where we had not previously gained any experience,” underscores Steven Pauli. The company’s aim is to achieve greater Investing in product range expansion Elematic, 37801 Akaa, Finland Opinion may well be divided on learning that a small family-run company has decided on investing in a capital-intensive project during eco- nomically difficult times. It was primarily their instinct for assessing market demand that led Pauli Beton N.V, a family business, to invest in a new production line for prestressed hollow core slabs. “Of course, it wasn’t just a gut feeling,” emphasises Steven Pauli, one of the com- pany’s four managing directors. Experience gained over the years in a continually changing market plus the possibility of being able to react more flexibly to customer demand both gave impetus to this very important decision for their firm.
Transcript of Trade Journal for the Concrete Industry - Elematic, 37801 Akaa, … · 2012-12-22 · prestressed...
CPI – Concrete Plant International – 6 | 2012 www.cpi-worldwide.com136
PRECAST CONCRETE ELEMENTS
With its 174 m in length, the modern hall structure has become thenew showcase for Pauli Beton. Construction of the new hall and production line commenced in September 2011.
View of the new production line for prestressed hollow-core slabs.
The concrete mixing plant, in the background, with its 2.25 m³ planetary mixer for supplying the production line with concrete.
Silos inside of the production hall for sand and aggregates ensure uniform moisture content when producing concrete.
Michael von Ahlen, CPI worldwide, Germany
The Pauli Beton precast concrete produc-tion facilities have been in existence sincethe 1950s and have their roots in the north-western part of Belgium. From the outset,the company’s core business has been themanufacture of concrete blocks and non-stressed reinforced wall and floor elements.The company has been headed by the sec-ond generation of the Pauli family since2003 with four family members Steven,Griet, Jean-Marie and Bart sharing thefirm’s management. Although the division of
tasks is clearly defined, work is carried out“hand in hand”.
The decision to expand the product rangewas made at the end of 2010. Elematicwas chosen for the prestressed hollow coreslab production line after an intensivesearch for a suitable business partner andquite a number of meetings for consulta-tions.
“Elematic gave us the impression of beingthe most professional and the most down toearth at the same time. It wasn‘t just a mat-
ter of their expert advice and the profes-sional support of their Finnish commission-ing team; our interpersonal contacts werealso out of the ordinary,” explains StevenPauli, who is responsible for purchasingand finance at Pauli Beton. Site visits tofunctioning facilities were a decisive factorin finally tipping the scales towardsElematic equipment. “During economicallydifficult times, a large investment carries acertain risk, and more especially so in anarea where we had not previously gainedany experience,” underscores Steven Pauli.The company’s aim is to achieve greater
Investing in product range expansionElematic, 37801 Akaa, Finland
Opinion may well be divided on learning that a small family-run company has decided on investing in a capital-intensive project during eco-nomically difficult times. It was primarily their instinct for assessing market demand that led Pauli Beton N.V, a family business, to invest ina new production line for prestressed hollow core slabs. “Of course, it wasn’t just a gut feeling,” emphasises Steven Pauli, one of the com-pany’s four managing directors. Experience gained over the years in a continually changing market plus the possibility of being able to reactmore flexibly to customer demand both gave impetus to this very important decision for their firm.
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PRECAST CONCRETE ELEMENTS
Max-Paul-Straße 188525 Dürmentingen / GermanyPhone: +49 (0) 73 71 / 5 00 - 0Fax: +49 (0) 73 71 / 5 00 - 111Mail: [email protected]
Maschinenfabrik GmbH & Co. KG
The experts in Prestressed Concrete Technology.
PAUL supplies
Prestressing installations incl. • planning workAnchor grips• Prestressing machinery• (single-/multi-stressing jacks)Strand pushing and cutting equipment• Automatic prestressing machines for • railway sleepersPrestressing equipment for bridge • construction(prestressing cables and stay cables)
Stability.
Prestressing of precast concrete elements
Alle Motive, Halbe Seite hoch, de-en-es-pt-fr-it-ru-pl.indd 1 02.12.2010 10:37:51
customer fidelity through expanding its product range and to beable to react more flexibly to market demand.
As Pauli Beton had formerly had no experience in manufacturingprestressed precast concrete flooring, the firm sought in-depthadvice from Elematic, in particular concerning the choice betweenextruder and slipformer methods. The decision fell to the slipformertechnology because, amongst other things, it is also possible tomanufacture T- beams, solid slabs and ribbed slabs besides pre-stressed hollow core slabs.
The starting point for this latest production line is a complete newhall structure of 174 m in length and 21 m in width. It shelters fourproduction tracks each 150 m long and 1,200 mm wide and canbe optionally expanded to six tracks. A new concrete mixing plantfrom Damman-Croes, including silos located indoors for sand andaggregates, also forms part of the investment. This 2.25 m³ plane-tary mixer supplies the production line with concrete. ELiDIST soft-ware from Elematic oversees the fully automated transfer of con-crete to a fly bucket and its further distribution at the slipformer.
Pauli Beton utilises a high-quality, quick-hardening concrete of com-pressive strength class C 50/60 for manufacturing prestressed hol-low core slabs. The shuttle, with a capacity for 2 m³ fresh concrete,can supply the slipformer extremely rapidly. The current main focusof production is on slabs 600 mm wide and 160 mm high; in thiscase, two 600 mm wide prestressed hollow core slabs are alwaysmanufactured in parallel on one casting bed. These elements of600 mm in width are particularly interesting for smaller buildingcontractors, since only lightweight machines are needed for tran-shipping and mounting them at a construction site. With minor mod-ifications to the slipformer, it is possible to manufacture prestressedhollow core slabs with a width of 1,200 mm and 400 mm in height.At the present time, Pauli Beton produces slabs with a maximumheight of 200 mm.
The facility’s key component, the Slipformer EF 5000, travels alongthe rails of a casting bed. Varying nozzle units allow 7 or 9 cavitiesto be set into a width of 1,200 mm. An overhead bucket gantry EB812 transports the concrete from the shuttle, thereby bridging a dis-tance of maximum 13 m to the farthest part of a casting bed.Repositioning the slipformer can be carried out rapidly, but only bycrane. At Pauli Beton, 3 tracks are currently produced in one day’sshift.
The shuttle system transports fresh concrete at a speed of 2.7 m/s tothe slipformer
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One day after the slabs have been manufactured, a type EL 1100fully automatic saw comes into action. This is able to execute longi-tudinal, transverse and also diagonal cuts at any angle desired from0 – 180°. The saw can sever elements up to 400 mm thick. A cross-beam from Elematic is employed to hoist the slabs. It is suspendedfrom two cranes functioning in tandem, i.e. operating simultaneous-ly, for transhipping the elements. To maintain seamless operations,three cranes are installed on the production line. This means that ele-ments can be transhipped and, at the same time, e.g. the slipformercan be repositioned.
For operations in winter, the production line has been equippedwith heating so that the concrete can harden more rapidly atfavourable temperatures for further processing.
Pauli Beton possesses three semi-trailers, which their customers canuse for transportation to a construction site. In this way, time spentfor logistics can be kept to a minimum. Once the elements havebeen loaded, the casting bed is prepared for the next casting pro-cedure. The multi-functional BedMaster now goes into action. Thismachine carries out several work stages at once. It cleans a castingbed to a dust-free state plus oils it at a speed of 60 m/min. Duringthis same time, the BedMaster is drawing the prestressing strands forthe following casting procedure at a speed of 30 m/min from acasting bed’s passive end. At Pauli Beton, an EL 255/200 multi pre-stressing device ensures that prestressing is carried out uniformly.The group prestressing unit is also ideal from an occupational safe-
ty viewpoint, since, amongst other things, it reduces the time need-ed for prestressing to a minimum.
The Elematic system is perfectly harmonised with the workflows atPauli Beton making for efficient production directly in tune with cus-tomer demand. Stockpiling costs are kept to a minimum as no arti-cles are produced for stock. For the near future, in case of a furtherincrease in orders, Pauli Beton is optimally positioned with theoption of commissioning two more production tracks. By the end of
The Slipformer EF 5000 during production The overhead bucket gantry bridges the distance in transportingconcrete between shuttle system and the slipformer
The slipformer can be repositioned using one crane track The Elematic lifting-beam can transport two elements of 600 mmwidth simultaneously
Even diagonal cuts at any angle desired from 0 – 180° are possible with the Saw EL 1100
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PRECAST CONCRETE ELEMENTS
Thermomass™
For more information, please call (800) 232-1748 or visit us online at
www.thermomass.com!
X- Series Connector
Thermomass presents the latest advancement in insulated concrete sandwich walls...
This new development:
Provides torsional resistance for the fascia wythe in a non-composite cladding wall panel
Provides higher levels of composite action in structurally composite sandwich wall panels
Eliminates solid concrete sections in load-bearing panels
Maintains composite action across thick insulations
Provides additional support at localized areas for signage and canopies
The X - Series Connector works in unison with Thermomass’ non-composite sandwich wall system (System NC) allowing precasters to suspend the fascia wythe of wall panels with more than 125mm (5-in) of insulation. It also allows precasters to create highly composite, load bearing or cladding sandwich wall panels.
this year, Pauli Beton is still aiming to begin operating a recyclingplant including excess water processing using a filter chamberpress. �
The multi prestressing device does not just work rapidly, it is also exemplary in terms of occupational safety
The multi-functional BedMaster performs several functions simultaneously on the production line: cleaning, oiling, drawing out strands for prestressing
FURTHER INFORMATION
Pauli-Beton N. V.Industrielaan 193730 Hoeselt, BelgiumT +32 89 411300F +32 89 [email protected]
ElematicAirolantie 237801 Akaa, FinlandT +358 3 549511F +358 3 [email protected]
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