weckenmann anlagentechnik gmbh & co. kg, 72358

CPI – Concrete Plant International – 3 | 2015 www.cpi-worldwide.com220

PRECAST CONCRETE ELEMENTS

The building contractor 1st Stroyfond fromNovosibirsk had already invested in abrick-making production line of its own froma German supplier in 2009 and had got toknow and value the quality of Germanmechanical engineering. For this reason italso turned to Anton Ohlert from Moscow,the agency for Weckenmann Anlagentech -nik GmbH & Co KG in Russia and the CIS,for the next step – a plant for the manufac-ture of precast concrete elements. Until nowthe precast elements had been procuredfrom various suppliers in the vicinity andalso further away. However, the scope ofthe building projects made self-productionworth considering.

In 2012 the top management from Armatonvisited a reference customer of Wecken -mann in St. Petersburg and before the yearwas out they had already been to theWeckenmann headquarters in Dormet -tingen, Germany. Agreement was reachedin 2013: A state-of-the-art plant for the man-ufacture of precast elements was to be builton a greenfield site. The development of amodern construction system, the obtainingof the required permits for the erection andoperation of a plant as well as the devel-opment of the site led to the start of con-struction in May 2014. The complete proj-ect has a volume of 1.7 billion roubles.

In order to realise this demanding projectwithin the given framework, Armaton chosethe German mechanical engineering com-pany Weckenmann as general contractor.

In the last few years Weckenmann hadrealised several projects of a similar sizeand complexity as general contractor inRussia and other countries. Under the proj-ect leadership of Weckenmann the well-versed team from Weckenmann (overallmanagement, circulation plant and station-ary production), EVG (reinforcementplants), Nordimpianti (hollow-core slabplants) and Teka (mixing plant) supplied asolution tailored to the customer’s needs,

New precast plant inaugurated in SiberiaWeckenmann Anlagentechnik GmbH & Co. KG, 72358 Dormettingen, Germany

A complete plant for precast concrete elements, an annual capacity of 70,000 m² of living space, from the groundbreaking ceremony to thefirst concrete in less than two years – that was the vision of the Russian concrete specialist Armaton and at the same time the challengethat faced the specialists from Weckenmann, which oversaw the construction of the new plant as general contractor.

Circulation plant with preparation for sandwich wall production Concrete distributor with compaction station

Shuttering store for the Weckenmann M-series shuttering profile Control centre of the WAvision master computer

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which went into production on 13 March2015 during an impressive opening cere-mony in the presence of the RussianMinister of Construction Mr Michail Menj,the Governor Mr Vladimir Gorodezkij, themayor of Novosibirsk Mr Anatolij Lokotj,the personal consultant of the Russian pres-ident in Siberia Mr Nikolai Rogozhkin andSenator Nadezhda Boltenko.

Getting this far has been demanding andthe schedules were tight. Overall projectleader Wadim Grünwald from Wecken -mann commented: “In this project we wereable to fall back on our many years ofexperience in projects as a general con-tractor in Russia and the CIS, and theproven team of suppliers in co-operationwith the Armaton project leadership underAlexander Kolesnikov also mastered thischallenge.”With regard to the interfaces and require-ments the individual components had to beadapted at an early stage to the buildinglayout and the media supplies.

Weckenmann Anlagentechnik, circulation plant and general contractor

The heart of the production is the flexiblecirculation plant with 42 pallets. Both solidand sandwich walls can be manufacturedon it. Solid floor components can also beproduced for special building objects.

The construction system was developedaccording to Armaton’s vision by the well-known design office Jakuschev in Moscow.Based on the element drawings, Wecken -mann’s shuttering department worked out aco-ordinated and optimally executed shut-tering system. The maximum number of ele-ments had to be formed with a minimum ofshuttering profiles. At the same time, asmany shuttering systems as possible had tobe in circulation and as few as possible instorage. The shuttering system fromWecken mann’s M-series formed the solu-tion for this. The shutters are equipped withintegrated switchable magnets. The M-series is very well suited to the manufactureof solid elements (floors, walls and facades)with custom chamfers and profiles. The M-series can also be used for sandwich ele-ments through the use of M-Top auxiliaryprofiles. The flexible shuttering system canalso be used at any time for another con-struction system. This allows Armaton to fol-low the developments in the building sectorwithout having to invest in new shutteringprofiles each time.

Armaton plans building types with 14, 17and 25 floors. The wall elements for this, up

to 425,000 m², come from the circulationplant. Special elements are produced onthe tilting tables also supplied. Ventilationshaft shuttering, stair moulds and driven pilemoulds are to be found in the stationaryproduction area.

The circulation plant is controlled by theWeckenmann WAvision master computer.The master computer coordinates the flowof production with data from the workpreparation, specifies the required shutter-ing profiles and supervises the manufactur-ing process. The concept is rounded off byproduct tracing as far as the open-air stor-age area. In WAvision, Weckenmann hasdeveloped a control tool that uses all avail-able data in the company and unites man-agement, production and reporting in a sin-gle system. This modular software solutionthus enables the linking of various systemsfor the control of automated precast ele-ment manufacturing so that there are nointerfacing problems between different sub-solutions.

Reinforcement plants from EVG

Such a large production volume and theassociated variance of the componentsrequired that the company produce its ownreinforcement elements. The manufacture oflattice meshes with different wire diametersand geometries had been a complex affairuntil then. Protracted conversions and inten-sive adjustment phases had been necessaryin order to achieve the desired result. Thistime-consuming process caused high costsas well as a considerably lower output.

For that reason Armaton invested in a fullyautomatic mesh welding machine of thetype FBE/158 from the Austrian manufac-turer EVG. The FBE welding machine itselfconsists of a laterally mobile welding por-tal, which carries individually controllablewelding units at distances of 100 mm. Thesingle spot-welding units can be specificallyactivated or deactivated as necessary.

In addition, the FBE combines a straighten-ing unit of the type RA-XE, which produceslongitudinal and transverse bars. The auto-matic wire diameter changer allows flexiblyusable wire diameters of 5-12 mm, withoutconversion times. Through this combinationboth door and window cutouts as well asdifferent wire diameters and geometries inone mesh can be realised without manualintervention.

In addition, EVG supplied an automatic stir-rup bending machine of the type PolybendPBC 2-12 with integrated 3D bending

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Weckenmann Anlagentechnik GmbH & Co. KG | GermanyTelephone +49 7427 9493 0 | www.weckenmann.com

CONSTRUCTING THE FUTURE

We have been developing and manufacturing formwork profile systems, machines and plants for almost 50 years.Weckenmann is your full-service partner in the field of installations for the production of precast concrete plants. We develop the appropriate formwork system for your plant and your prod-ucts – the complete solution from one source.

For more information visit:www.weckenmann.com/formworkprofiles

ADVANCED FORM-WORK PROFILE SYSTEMS DEVELOPED BY THE SPECIALIST




mechanism for the production of stirrupsand rebars. This enables the processing ofboth cold and hot-rolled, randomly woundor coiled material off the coil with a diame-ter of 6-12 mm. The required reinforcementcages are manufactured from the individualelements at vertical workstations.

Mixing plant from Teka

The necessary mixing plant was suppliedby Teka. A weighing and mixing plant wasselected with two planetary mixers of thetype TPZ 3000 with concrete dischargeinto two bucket tracks. During the alterna-tive production of ready-mixed concrete,the concrete is discharged directly into thetruck mixers. The mixing plant enables pro-duction of around 80 m³ ready-mixed con-crete per hour with simultaneous use ofboth planetary mixers. One mixer can alsobe used alone for the production of about40 m³ ready-mixed concrete per hour.

The aggregates are stored in a round silosystem with a storage capacity of approx.408 m³. The mixing plant is fed by a charg-ing hopper with grab-crane unit; feeding

with a charging hopper for trucks is alsoprovided for. Microwave sensors for themeasurement of the sand moisture level inthe silos, moisture and temperature meas-urement in the mixer, protective devices forvoltage fluctuations in the control system,consistency measurement for ready-mixedconcrete and remote maintenance viaInternet ensure smooth processes in theplant.

An emergency computer as well as the pos-sibility to continue to operate the plant man-ually guarantees additional operating relia-bility.

The two track carriages of the Wecken -mann bucket track each have a volume of 2m3 and supply the circulation plant and theprestressed hollow-core slab productionwith the appropriate concrete qualities.

In total, up to 420,000 m³ of concrete canbe processed per year in the new plant.Such a modern plant would be incompletewithout a fresh concrete recycling unit. Allconcrete sludge from the mixers, the trans-port buckets of the bucket track system and

the cleaning of the truck mixers is fed to therecycling plant by means of an collectingtank. Water with cement is separated fromaggregates in a catchment tank. Depositssuch as sand and crushed stone are sepa-rated out and stored on heaps by means ofspiral conveyors. The recycling water canbe fed both to the mixing plant for re-use orcan be used for the cleaning of the truckmixers.

Dosing equipment for dyes (dry and liquid)was integrated for the production ofcoloured concrete (fair-faced concrete).The respective recipes are stored in the con-troller.

Prestressed hollow-core slab production from Nordimpianti

Nordimpianti supplied the prestressed hol-low-core slab production equipment for ele-ments with a height of 220 mm and a widthof 1200 mm. The fully automated produc-tion consists of six casting beds, each ofwhich is 120 m long and is equipped witha single-wire stressing and detensioning sys-tem. Other equipment supplied included

FBE/158 mesh welding plant from EVG Polybend PBC 2-12 with 3D bending mechanism from EVG

The necessary mixing plant for the newplant was supplied by Teka

TPZ 3000 planetary mixer


CENTRAL EUROPE 201611. – 12. February 2016

The ZBI Congress, which had its premiere in2014 and was successfully repeated in 2015,will become the ICCX Central Europe next year.The organisers of the ICCX Central Europe arelooking to address participants beyond the borders of Poland. The target group of theevent is the central European states. As is usualfor an ICCX, the conference agenda with the accompanying trade exhibition will run for twofull days.

ICCX events have been taking place in variousplaces in the world for 15 years.

Ossa, Poland

International Concrete Conference & Exhibition

www.iccx.orgMBK Maschinenbau GmbHFriedrich-List-Str. 19 | 88353 Kisslegg / GERMANYTel +49 (0)7563 9131-0 | Fax +49 (0)7563 2566www.mbk-kisslegg.de | [email protected]

• Diameter range up to 530 mm

• Diverse range of accessories

• High productivity and flexibility

• Cage length up to 18 m• Wire diameter of re-bars up to 25 m• Extreme reliable and long life span due

to stable construction• Conform to the latest safety standards• Different cage geometries possible, like round,

triangle, square and rectangular

www.mbk-kisslegg.de

VSM

STRONG CONNECTIONS

Cage welding machinefor the production of

round, triangle and squarecages for driven and boredpiles, columns and beams.




the half-portal concrete distributor, an angu-lar concrete saw (for the cutting of the con-crete elements up to 520 mm with cuttingangles from 0 to 180°), the multifunctionbed cleaner, the lifting equipment and atransport system.

The production capacity was calculated bythe planning engineers to be 850 m² ofprestressed hollow-core slabs per workshift. The high level of automation of theproduction line, which is based on extrusiontechnology, means that only 5 persons arerequired per shift. The plant now produces

prestressed hollow-core slabs with spans ofup to 9 m and a load-bearing capacity of800 kg/m².

The production of these lightweight pre-stressed hollow-core slabs offers both themanufacturer and its customers advantagessuch as a higher live loads with a lowerdead weight. The prestressed hollow-coreslab system enables a reduced concreteconsumption and at the same time a lowerheat requirement in the manufacture.

Following the commissioning of the individ-ual areas, the detailed training of the oper-ators and the maintenance staff takesplace. Here, too, the customer can rely onthe experience of the qualified suppliers.

“A quick handover of the general contrac-tor projects and thus fast market positioningare crucial advantages that have a majorinfluence on the long-term corporate suc-cess of our customers”, says Karl-WilhelmBögl, head of the Project Department atWeckenmann. In the final stage of devel-opment the plant will have a productionoutput of 300,000 m² of living space peryear.

At Weckenmann the next project of a simi-lar order of magnitude is already ready fordelivery. Once again here Weckenmann isthe central point of contact for the customer.

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Inauguration ceremony at Armaton

Prestressed hollow-core slab production from Nordimpianti

Concrete saw from Nordimpianti

FURTHER INFORMATION

OOO ZKPD ARMATONPlatforma Street 3307 km, Building 17Tolmatschevo, 633100 Novosibirsk RegionRussia

Weckenmann Anlagentechnik GmbH & Co. KGBirkenstraße 1, 72358 Dormettingen, GermanyT +49 7427 94930, F +49 7427 [email protected], www.weckenmann.com

EVG Entwicklungs- und Verwertungsgesellschaft m.b.H.Gustinus-Ambrosi-Str. 1–3, 8074 Raaba/Graz, AustriaT +43 31640050, F +43 [email protected], www.evg.com

Teka Maschinenbau GmbHIn den Seewiesen 2, 67480 Edenkoben, GermanyT +49 6323 8090, F +49 6323 [email protected], www.teka.de

Nordimpianti System SRLVia Erasmo Piaggio, 19/A, Zona Industriale Chieti Scalo66100 Chieti (CH) – Abruzzo, ItalyT +39 0871 540222, F +39 0871 [email protected], www.nordimpianti.com


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