products of maximum quality and precision through exact

CPI – Concrete Plant International – 5 | 2013 www.cpi-worldwide.com210

PRECAST CONCRETE ELEMENTS

Prilhofer Consulting was commissioned toplan the new double wall plant at theMettenheim site – and for a good reason,too: when the plant for the production ofprecast slabs with in-situ topping was com-pletely re-planned in 1996, it was alsoPrilhofer Consulting who, during the plan-ning, foresightedly positioned and dimen-sioned the mixing plant – supplied byDoubrava and Wiggert – in such a waythat the new double wall plant can today

be supplied with concrete from the samemixing plant without this leading to pro-duction bottlenecks for either of the works.

The plant was planned to meet the high cus-tomer demands and extremely short deli-very times and particular importance wasattached to work efficiency, product qualityand the ability to react quickly. innbau doesnot manufacture mass-produced goods, butattaches importance to supplying high-qua-lity precast concrete elements to satisfiedcustomers.

Economical and time-optimised solutions for individual construction

With the commissioning of the new doublewall plant in April 2013, innbau relocatedits complete production capacity to theMettenheim site. This entails logistic advan-tages – ultimately for the customers as well.Apart from the complete production, theMettenheim site also accommodates theadministration and the technical office. Inthe technical office the projects have beenprepared especially for the precast elementproduction using Nemetschek Allplan sinceas far back as 1998. Double walls andsolid walls are planned on 5 workstationsat present; due to the hybrid mode of ope-ration of the software, the planners canchoose between the 3D model and classictwo-dimensional planning work at any time.

The results of the planning in AllplanPrecast can be transferred directly via theappropriate module to the master computerin the works for the determination of theproduction data and are also available aselement diagrams as well as overview andinstallation diagrams, formwork and reinfor-

cement diagrams, etc. Order data such asproject name and number, client, buildingproject, various addresses, etc. can be sentautomatically to the commercial depart-ments. In addition the quantities, weightsand number of items determined in theCAD for precast elements, built-in compo-nents, reinforcements and all other invoice-able items can be used for further commer-cial processing without having to enter thedata again.

For the new plant Prilhofer Consulting distri-buted the machines and plants for the dou-ble wall production over several levels inthe new hall, which is located exactly bet-ween the floor production hall and the hallfor the production of special parts.

Albin Schuster, acting partner, describesthe goals that were pursued in the planningas follows: “Of course we can see theadvantages of automation; but only whenand where it also makes sense for us. Withthe core elements for the new plant, forexample the formwork robot, we paid atten-tion from the outset to maximum productivi-ty and automation. In other areas, however,in which we can still get along with lessautomation in view of the present extent ofutilisation and product range, we investedalso only so much that we can immediately,simply and quickly extend our capacities ifwe need to or add new products.”

In principle the double wall production atinnbau passes through the well-knownsteps: Cleaning, shuttering, placement ofthe built-in components, installation of thereinforcements, concreting, hardening,demoulding and placing into storage.These work sequences of the pallet circula-

Products of maximum quality and precision throughexact planning and optimised prefabrication

innbau-beton GmbH & Co. Fertigteilwerke, 84562 Mettenheim-Hart, Germany

The innbau company has been active in the concrete industry in the southeastern region of Bavaria in Germany since the beginning of the1970s. Although exclusively ready-mix concrete was produced at first, the decision was very quickly taken to produce and market precastslabs with in-situ topping as well. The precast slab with in-situ topping, which has a market share of well over 70% in Germany, is still oneof innbau’s most important products today. Further acquisitions as well as the building of a special new plant for precast slabs with in-situtopping in 1996 at the Mettenheim site have made innbau one of the largest manufacturers in South Germany with production of around450,000 m2 of precast slabs with in-situ topping.In 1998 innbau seized the opportunity to take over an insolvent company. With only a little conversion and modernisation work, this allowedthe production of double walls as well from that point on. However, with around 50,000 m2 of double wall elements in recent years, the pro-duction capacity of the plant was continuously at full stretch, and so the decision was taken in 2010 to begin with the planning of a newplant that would reflect the state of the art and enable innbau in future to produce precast concrete elements with maximum productivityand quality and with sufficient reserves of production capacity.

The double wall becomes a work of art inthe truest meaning of the words at innbau

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Production Engineering andAutomation Systems for thePrefabricated Concrete Element Industry| Stationary line production| Tilting station| Pallet circulation plants| Transport and handling systems| Multi-Function-Shuttering-Robot (MFSR)| Concrete distribution systems for all purposes| Compacting systems| Finishing equipment| Shuttering systems| Shutterings for special purpose elements| Moulds for garages/moulds for rooms/special purpose elements| Shutterings for skeleton building systems| Moulds for columns/moulds for girders/moulds for TT-elements

SOMMER Anlagentechnik GmbH | Benzstraße 1 | D-84051 Altheim/Germany

Phone: +49 (0) 87 03 / 98 91-0 | Fax: +49 (0) 87 03 / 98 91-25

[email protected] | www.sommer-landshut.de

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tion plant, which was supplied by SommerAnlagentechnik, are organised by an IPS-Leit2000 master computer from SAA engi-neering, which directly accesses the data ofthe Nemetschek software. The master com-puter directs the pallets at the right time tothe right station, always according to theproduction requirements for the respectivestructural element. Currently a total of 45 pallets measuring 10.5 x 3.6 m are incirculation at innbau, on which precast

slabs with in-situ topping up to a thicknessof 400 mm, double walls with a wall thick-ness of up to 500 mm and solid walls witha wall thickness of up to 140 mm can beproduced.

An MFSR shuttering and demoulding robotfrom Sommer Anlagentechnik operates atthe shuttering and demoulding position andcan cope with a maximum productioncapacity of 6 pallets per hour.

Apart from setting and removing the shutte-ring, the MFSR robot also plots the outlinesfor built-in components on the pallet. It pla-ces removed shuttering in front of the auto-matic cleaning station for the lateral stopends and, by means of an optionally usableactive store, reusable shuttering is used forthe next pallet immediately after cleaningwithout first having to be sorted back intothe magazine.The complete processing of the steel takesplace on two higher levels with machinesand plants from progress Maschinen &Automation. The lattice girders in differentversions are kept in a store and taken outwhen needed, cut to length and taken tothe respective pallet, where they are manu-ally placed in position. The lattice girdershears were similarly supplied by progress.innbau does not use standard meshes, butproduces all required reinforcement meshesitself using the M-System Evolution meshwelding plant from progress. The requiredlongitudinal and transverse wire is suppliedoff the coil, straightened and cut to lengthbefore being processed further in the meshwelding plant. While the individual meshesare produced in accordance with the requi-rements specified by the software from bau-bit, the master computer from SAA in turnorganises the on-time and correct place-ment of finished meshes on the respectivepallets to be worked on using a handlingspreader bar.

Quality control by means of laser projection system

Pallets fitted with built-in components andthe complete reinforcements are checked

The circulation system has areas divided over several levels for work that is critical to thecycle time, such as the turning of the double walls, smoothing or the production of insulateddouble walls.Other areas, for example for shuttering, installation of reinforcements and con-creting, have double tracks in order to allow continuous working without changing pallets

The projects, which are optimised for the precast construction method, are planned by innbau in advance in the minutest detail. This carefulness pays off – and the results are impressive. Shown here is the visualisation of a multi-story building in Munich, which was erected entirely using precast elements from innbau



A B

CD

E

10

1

2 3 4 5 7

6 8 8a9

1 Shuttering and demoulding robot2 Carpentry3 Built-in components4 Reinforcement5 Laser / quality control6 Transfer area

7 Concreting / compacting8 Turning station8a Smoothing platform above

turning station9 Tilting station10 Discharge cart

Mesh welding plant on the upper levelA Transverse bar handlingB Longitudinal bar handlingC Welding plantD Removal position with mesh craneE Mesh buffer

www.saa.at

Intelligent Software Solutions for Precast Concrete Plants

SAA Engineering GmbhGudrunstrasse 184/4A-1100 Vienna/Austria

T +43-1-6414247-0*E [email protected]

Adaptability is our Passion

Intelligent Soffor Precast C

SSSAAAAAASAAAAAAA EEnEnEn EnEnEnEnEnEnEnnnnggigiginginggingingingininneeeeeeeeering GmbhGGGuGuGuGudGudGududGudududG ddrururururunrunnnnnststststrasse 184/4AAAAAAAAAAA-1-1-1-11-11111111000000 Vienna/Austria

TTTT +43-1-6414247-0*E [email protected]

www.cpi-worldwide.com




The MFSR shuttering robot places the shuttering on the pallets with an accuracy of +/- 1 mm. Later on the shuttering can be removed againautomatically from the pallets just as fast as it was placed on them.

For the steel processing, which is located above the concrete processing, the steel off the coil is first straightened, cut to length and thenprocessed further on the fully automatic mesh welding plant. The mesh store enables continuous and very efficient production by the steel processing plants.

The ceiling lasers enable the precise final checking of the elements tobe concreted. The individual work processes that were required toassemble the pallet can be visualised by means of the control computer for the laser.


Dimensionsin new

THINKSoftware & Services for thePrecast Concrete Industry

Nemetschek Engineering GmbHStadionstrasse 6

5071 Wals-Siezenheim

Salzburg / Austria

phone: +43 (0) 662 85 41 11-0

fax: +43 (0) 662 85 41 11-610

[email protected]

www.nemetschek-engineering.comwww.cpi-worldwide.com CPI – Concrete Plant International – 5 | 2013


once again using a laser projection systembefore concreting. The control computer forthe ceiling laser, which is located directlybeside the workstation for the pallets, enab-les the operator to visualise the work pro-cesses, so that the complete configurationof the pallet can be reconstructed here stepby step. This is made possible by the lasersoftware being able to access the corres-ponding master computer data.

After the final check the elements are con-creted at the Sommer concreting station;the concrete is delivered from the alreadypreviously existing mixing plant. This ismade possible by a bucket conveyor fromDudik, which drives under the 1.5 m3 pla-netary mixer from Wiggert in the mixingplant and then serves the concrete distribu-tor in the new double wall plant following ajourney of almost 20 metres. The Vario-Swing compaction system on the concre-ting and compaction station operates parti-cularly quietly in comparison with other sys-tems, which considerably reduces the expo-sure of the employees to noise. In addition,the compaction ensures high-quality surfacesin fair-faced concrete quality on the shutter -ing side, which innbau’s customers value agreat deal.The drying and subsequent treatment of theelements takes place in four rack towerswith a total of 54 storage places, which areserved by a fully automatic storage andretrieval machine. Right at the top of thehall, on a further level, three workplacesare already provided for a fully automaticsmoothing facility, which is intended to pro-vide for optimum surface quality on the fil-ling side as well in the production of solidwalls. In case of double wall production theoptimum organisation of the pallet transportroutes in interaction with the storage andretrieval machine is indispensable for highproductivity. The hardened upper shells areremoved from the hardening chamber andlaid onto a freshly prepared lower shell ona turning station. The resulting element iscompacted again and placed back into thehardening chamber. Finally, after harde-ning, the elements are removed, taken tothe lifting station, placed in an upright posi-tion by a tilting device and lifted up.Ideally the finished elements are loadedimmediately onto trucks or at least intotransport frames, so that warehousing isbarely required. The printouts of the pallet-accompanying plans created automaticallyby the master computer as well as the orga-nisation of labelling help to correlate theelements correctly at all times throughoutthe production process as well as in the sub-sequent logistics in the warehouse or at thebuilding site.

After a journey of less than 20 m the bucketconveyor from Dudik brings the concretefrom the mixing plant in the neighbouringhall to the automatic concrete distributor,which fills the finished pallets with concrete.The subsequent compaction provides forperfect surface quality of the precast con -crete elements, which is valued by innbau’scustomers.




Highest requirements for product quality– but also for safety in the plant

Despite the high degree of automation ofthe plant, manual work steps may still benecessary for demoulding, the positioningof built-in components, the checking of rein-forcements, compaction or the positioningof the upper shell on the lower shell. Theplant safety concept provides for the indivi-dual activation and deactivation of separateautomatic areas. The associated logic forthis is freely programmable.

Hence, no rigid one-track safety concept isdictated. In fact, over the course of time, inn-bau can develop an entirely individual con-cept based on its own experience, enablingthe highest possible degree of automationand at the same time maximum flexibility inthe operation of the plant.

The safety concept is programmed using acontroller that can access the master com-puter data and, conversely, can also influ-ence the positioning of the pallets in theplant.

Modern on-line machine visualisation for the overview, error analysis andmaintenance

A web browser and Internet access as wellas theoretically any mobile terminal devicesuch as an iPad is sufficient, provided onehas the appropriate access rights, to bringthe inner workings of the pallet circulationplant graphically onto the screen. The terminals of the master computer thusoffer an overview of the state of the plant,current error messages and even details foreach machine (e.g. the sensor-laden liftingtraverse of the storage and retrieval machi-

ne) at all times. Hence, all plant informationis continuously available, which enablesparticularly fast intervention where neces-sary and thus secures the high productivityof the plant.

Well equipped for the future

With more than 80 employees innbau pro-duces and delivers precast concrete ele-ments in southeastern Bavaria within a radi-us of around 100 km. innbau is outstanding -ly well equipped for the future with the newdouble wall plant, which represented atotal investment of almost 8 million Euros.The customers, who mainly realise residen tial,commercial and hotel construction projectswith the precast concrete elements from inn-bau, particularly value the very short deli-very times and the just-in-time production.

In future the insulating double wall couldbecome particularly important, especiallyin the aforementioned projects, on accountof the energetic requirements for buildings.innbau is already equipped now for theproduction of such products with its newplant, and over 250 regular customers areproof of the trust placed in the continualquality of the products leaving innbau’sworks site every day.

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The hardening chamber with the storage and retrieval machine is located right next to the turning station

The modern production facilities at innbau are continuously monitored on the terminals of themaster computer – in principle, however, any computer or mobile terminal device with a webbrowser, Internet access and the appropriate access rights is sufficient to get information fromanywhere about the state of the plant.


217


The storage area at innbau is hardly needed for precast slabs with in-situ topping or doublewalls, since these are produced just-in-time for the respective project and only the shorteststays in the storage area are usually necessary. In addition to precast slabs with in-situ top-ping and double walls, innbau also manufactures stairs and balconies for example, as wellas all kinds of special elements required for the completely supplying of projects for residential and commercial construction.

FURTHER INFORMATION

Innbau-beton GmbH & Co. Fertigteilwerke Kraiburger Straße 1 84562 Mettenheim-Hart, GermanyT +49 8631 37700 . F +49 8631 [email protected] . www.innbau.de

Prilhofer ConsultingMünchener Str. 1, 83395 Freilassing, GermanyT +49 8654 69080 . F +49 8654 [email protected] . www.prilhofer.com

Nemetschek Engineering GmbHStadionstraße 6, 5071 Wals-Siezenheim, AustriaT +43 662 8541110F +43 662 854111610www.nemetschek-engineering.cominfo@nemetschek-engineering.com

Sommer Anlagentechnik GmbHBenzstrasse 1, 84051 Altheim, GermanyT +49 8703 98910 . F +49 8703 989125 [email protected] . www.sommer-landshut.de

SAA Software Engineering GmbH Gudrunstr. 184/4 1100 Wien, AustriaT +43 1 64142470 . F +43 1 641424721 [email protected] . www.saa.at

progress Maschinen & Automation AG Julius-Durst-Straße 10039042 Brixen, ItalyT +39 0472 979100 . F +39 0472 [email protected] . www.progress-m.com

Dudik International Kübelbahnen und Transportanlagen GmbH Mackstraße 21, 88348 Bad Saulgau, GermanyT +49 7581 8877 . F +49 7581 4692 [email protected] . www.dudik.de

Software & Service GmbHGimpelstraße 3, 5302 Henndorf am Wallersee, AustriaT +43 6214 20175 . F +43 6214 [email protected] . www.baubit.de

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