Efficient building with customized wall elements of SOLID QUALITY.

The future of building has already begun.

redbloc – THE ONLY SYSTEM THAT ECONOMICALLY PRODUCES PREFAB ELEMENTS MADE OF GROUND SOLID BUILDING BLOCKS.

redbloc - The world wide unique system that produces

prefab walls effi ciently and economically from solid ground

building blocks has now been further developed.

Since that the redbloc technology

has successfully been established in the last 10 years in many

European countries, now there is the new generation of redbloc

prefab system available?

redbloc compiles – according to your requirements – the layout

of the equipment, subsequently plans and sells the entire

production plant as a turn-key plant including assembly and

commissioning of the line.

Trend-setting

System solutions._Evolutionary further development in prefab production The proven redbloc technology is based on a world wide unique dry adhesive system and enables a constant and cost optimized quality in production and assembly.

_Maximal fl exibility of material selectionWith the newly further developed redbloc system wall thicknesses from 10 to 51 cm can be produced. In the customary practice only one format is used. So no special formats are needed from your block supplier.Half stones, soffi t or reveal stones, height-compensation stones and special off-set stones are also not required. The wall element is constructed to the exact length including gaps or cut-outs. This is especially important with the use of fi lled building materials (fi lled with materials like perlite, mineral wool, insulating foam or other similar materials). There are no open cutting surfaces, neither on the wall ends nor on the window reveals.The processing of the blocks and wall elements is carried out exclusively with a dry method. The result – no moisture in the building elements and no drying time is need on the construction site.

_Just in timeAlready one hour after production of a wall element it is ready to be transported. The redbloc system does not require any iron reinforcement. The hi-tech product carbonfi ber will be used if required by normative specifi cations or by special formations of elements.

_From planning to start up We provide technology for a fully automated production of wall elements made of ground solid building materials like bricks, sand-line stone, pumice stone, light weight expanded clay blocks, aerated concrete blocks and precast concrete blocks from a wall thickness of 10 to 51 cm. For usage of this technology we draw up a licensing contract.

This license contract warrants that:

> All new developments from redbloc may be used

> The brand name redbloc® can be used

> We train your staff on our equipment

> You have access to fast and effi cient support to provide you with assistance when problems occur

> We support you with ordering spare parts and advice about repairs

> We provide competent advice for technical building issues

> You are provided with all the necessary certifi cate reports

that have been carried out for constructional approvals

in the EU as well as in Germany

You are provided with all the necessary certifi cate reports

that have been carried out for constructional approvals

in the EU as well as in Germany

02_03

With the optimized

redbloc prefab system wall elements can be produced even more

efficiently and cost effective.

The

plant.

_Advantages of the prefabrication system

> Fully automated process- turn key plant> Only one format per wall thickness – no special formats required> Production of individual prefab walls in thicknesses 10-51 cm> Exact production to the millimeter – no longitudinal cuts necessary> Just in time production of wall elements – only 1 hour from production to shipment> No cutting surfaces on wall endings and window reveals> All wall elements in tongue and groove> Constant quality of wall elements- no reclamations on the construction site> Own lintel production for every wall thickness> Integration of installation parts like roller shutter casing, belt winders etc...> Constant cost calculations- no surprises> Reduced waste through optimized cutting> Easy transportation and assembly system – re-useable iron lifters for assembly on site

The constructional drawing is imported into the

element processing software from NEMETSCHEK, based on

that the needed wall elements are calculated.

The assignment of the blocks is carried out by the wall

calculating software MBS developed exclusively for

redbloc by AGS Engineering.

Through a data interface, the contours of each wall element for a building are transferred to the production line. At this point all details (level, cutouts, typ of material, etc.) are taken from the constructional drawing and transferred to the software which calculates the wall elements. The wall calculation software, developed by AGS Engineering, examines all wall elements and calculates the placement of the blocks in the wall ele-ments. For that purpose the respective parameters are read out from the material data base and the setting of blocks in a wall element is calculated. Normative requirements like overlap measure of blocks are taken into account and length tolerances of the blocks are automatically corrected by the software. The MBS software is capable of calculating all types of wall elements and dimensions – thereof within the systems limitations and respects an optimized use of blocks with a max. reduced waste cut.

Simultaneously necessary additional components are taken into account:

> Fully automated insertion of carbon-fiber reinforcement strips according to constructional approvals

> Fully automated drilling of vertical holes for the lifting devices considering the center of gravity

of the wall element

> Cutouts for roller shutter casings, pulleys, as well as for lintels

> Additional cut outs for installations etc.

> Roof slopes and gable walls

> Calculation of the weight of elements for an optimized loading of the transport containers

> Calculation of material requisition for the ordering system

_Order managementCalculated wall elements are assigned to orders considering the sequence of assembly at the construction site as well as an optimized utilization of the production plant. It is possible to produce more than one ele-ment per production cycle. The size of elements can be related to the payload of the crane on the construc- tion site. The MBS software communicates in cycles with the production line and transfers continuously the next production order. These orders can be sorted manually in dependence of need or urgency. Before transference of data the current dimensions of the blocks are determined – necessary adjustments will be considered.

Wall calculating software MBS Operation panel productionSoftware NEMETSCHEK

The newly developed

wall calculating software MBS.

04_05

_Cutting optimizationThe cut of the block is already calculated by the MBS and optimization of the cut is regarded. The cut of the block is selected so that the least possible waste is generated and that the section can be used again. Both saws are constructed in a way that the cut of both sides of the block can be used for the current block row subsequently the waste from saw one will be transferred to saw two. In an optimized case the beginner and end piece of a block can be used. In case the wall is created following a grid the waste is minimized to the max. The used software algorithm takes in consideration that the wall element always starts with groove and ends with tongue – provided that blocks are moulded that way.

ROBOTICSRobot 1 unstacks the blocks from pallets and feeds the processing line.Robot 2 feeds the blocks to the saw and supplies the processing line with cut pieces.

SAWS Blocks are positioned in the first of two saws and blocks are cut to the mm.

THE PRODUCTION.

Grouping/Cutting/Measuring/Drilling

The production.The robot 1 starts with unstacking the pallets

as soon as the job order is transferred to the

production plant.

Robot 1 – feeds the production line, robot 2 – feeds saw 1 and 2 and provides cut pieces into the production line. The software MBS surveys the whole job in order to produce cut pieces in advance.

Blocks are taken by the robots by means of special designed grippers. The necessary unstacking algorithm is transferred dynamically with every block format. In case half full pallets are provided the robot automatically searches the actual layer.

_Grouping blocks and measurementThe grouping of blocks is carried out by calculation, necessary cut pieces are fed in front or in back of a layer into the production line. When a layer – besides the last end piece – is complete, the layer is compacted and measured. This measurement is the base for the cut of the end piece. By doing so, bigger tolerances of blocks in length are compensated. This end piece is fed into the production line after the measurement process.

GROUPINGthe end piece is cut by the second saw and inserted in the line after measurement.

DRILLINGexact calculation of the position for vertical lifting holes. The MBS software calculates the center of gravity and special drilling devices are drilling the holes.

06_07

Setting/Bonding/Carbon

The production.

SETTING OF LAYERS.

_Wall productionAt the end of the production line, the layers are newly positioned and compacted and put on circulating pallets by means of a layer gripper. After every set row the adhesive or bonding material is applied. Further the reinforcing carbon strips are inserted – when required – according to the input standards of the MSB software. The strips are inserted, tensed and cut. In sequence the next row is set. The pallet with the finished wall element is automatically moved to the next processing stage. _The adhesiveFor redbloc system a new innovative adhesive system comes to use. After 3 years of development time in collaboration with the technology group H.B. Fuller, redbloc developed a patented dry adhesive process for solid ground building materials. The 2-component system binds within a very short time and the wall elements can be further processed.

The patented 2-component adhesive is applied exactly to the millimeter on the block surface. After the spraying process the spray head is automatically cleaned.

Setting/Bonding/Carbon

The production.The layer gripper sets a new layer of blocks on the circulating pallet

Insertion of the carbon strips A new layer of blocks is set on the inserted and tensed carbon stripes

08_09

DIAMOND WIRE SAWPrecise vertical cutting

Cut for belt take-up reel

The finished cutout section of a wall

ENTRANCE TO SAW AREAThe finished walls are sent to the sawing area where the execution of cutting has been pre- calculated.

The

Saw area.The big advantage of the wire saw system is that

the sawing process is executed completely dry. Therefor this systems helps to reduce building times as

necessary times for dehydration of the walls on site are

reduced to the maximum. A central extraction system

of saws and drills guarantees a clean production plant.

Solid prefabricated walls with a height up to 350 cm can be cut with the new diamond wire saw.The wall thickness can vary in a range of 10 to 51 cm.

Possible cuts:

> Sloping roof

> Gable walls up to 45°

> Cut-outs of the bearings

> Sections for rafters or arches

> Sections for roof beams or stringers

> Vertical cuts

> All cuts on the outside contour of the wall elements

In principle it is possible to realize every imaginable three dimensional contour by means of the patented diamond wire saw. On both sides of the wire saw guiding rollers are attached in order to prevent the wall elements from tilting. The guiding rollers adjust automatically to the different thicknesses of the wall elements. Optional, a rotary grinder machine can be installed. This machine serves for cutouts like sockets, cutouts for lines but also miter cuts on wall ends can be executed.

By using the wire cut technology

the production can be carried out faster

and more efficient.

10_11

Compilation and

transport.

The

Lintels.

_Own lintel productionin a special designed rotary grinder machine grooves are ground into the building blocks. Subsequently reinforcement steel is applied and concrete is filled into the grooves.

The big advantage – lintels in all wall thicknesses can be produced with the same kind of blocks as used for the wall element production.

Just in time. By means of a fully

automated prefab production per shift (8 hrs) up to 400 m²

can be produced and shipped to the construction site.

And that with a constant high quali-ty and cost advantage of an industrial production.

_CompilationThe produced and finished elements are equipped with re-useable lifting devices and are put into transport containers. The compilation of additional needed parts, like screen shutter boxes is controlled by the software.

_Fast loading and shipmentby using inside loaders the containers can be shipped in no time.

Loading of transport containers by means of a bridge crane

Lowering and insertion of the inner loader into the transport container Loading is executed – ready for transport to construction site

12_13

ASSEMBLYOn the construction site, the biggest advantage of redbloc wall elements is the enormous saving of work time. One skilled worker and two laborers can erect up to 300 m² in one 8 hour shift.

Used with commercial or social housing buildings the redbloc system is even more efficient and economical. By means of use of prefab also big projects can be erected in a time which is unbeatable by conventional masonry. 4 teams – each with 3 workers – can easily erect up to 1.000 m² per shift. The result – on time completion and cost advantages.

In terms of cost and time efficiency the redbloc system is only comparable with light weigth constructions though having all advantages of massive building blocks.

The redbloc prefab system is the ideal combination of the advantages of both methods of construction and suitable for family houses as well as for commercial buildings. High quality for reasonable price.

1) Delivery is made by means of special trailers – that requires free access to the construction site. 2) After the ground plan is chalked on the foundation plate the assembly can be started.

3) The highest point of the foundation plate is determined by means of a lever. Based on that distance plates are set and leveled.

4) Setting of the wall elements into a fresh mortar bed. 5) Before setting the elements 2 oblique supports must be prepared. They hold and stabilize the wall in a plump position.

6) The oblique supports are fixed with screws on the wall as well as on the foundation plate. Afterwards the lifting devices of the wall can be removed. 7) After assembly the joints and edges are sealed with a special adhesive.

8) On the inside of the building a 20 cm wide tissue is applied. 9) The grid in the area of massive ceilings is made by means of lateral formwork angles which are glued directly on the wall elements.

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The future of construction.

_Assembly

14_15

redbloc Beteiligungsgesellschaft m.b.H. Eferdinger Straße 175 A 4600 Wels

Tel. +43 (0) 72 42 | 46 320-0Fax +43 (0) 72 42 | 46 320-14www.redblocsystems.cominfo@redblocsystems.com

REFERENCES

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