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CPI – Concrete Plant International – 2 | 2009 www.cpi-worldwide.com202

PRECAST CONCRETE ELEMENTS

The e xisting equipment at S.E. Concr etehad for t he mos t par t gr own old and anextension on the existing site was out of thequestion. Hence initial consider ation w asgiven to a ne w building on a ‘gr eenfieldsite’ in 2005.Once a suitable site was found with perfectmotorway connections close to t he existingmanufacturing facilities, planning was inten-

sified. The basic ques tion w as whet her tobuild the new production plant as a circula-ting pallet plant or , as up to no w, as a stationary pr oduction plant. The wides tvariety of pr oduction plants w ere t herebyinspected and their advantages and disad-vantages compared.The decision was finally made in fav our ofa classic tilting table pr oduction plant, but

using po werful mac hines for cleaning/oiling/plotting of t he tables as w ell as forthe concr eting and subsequent smoot hingof the concrete elements. The deciding factorwas in par ticular t he high demands wit hregard to the desired flexibility.

Planning/building phase

Avermann Masc hinenfabrik w as in volvedin t he planning of t he plant r ight from t hestart, toget her wit h its Scandinavian dis tri-bution partner CPT (Concrete Plant Techno -logy). A basic concept w as developed atan ear ly s tage t hat satisf ied Amber con’swishes and expectations at first go and onlyneeded to be specif ied mor e pr ecisely inthe details.

Contract negotiation wit h t he v arious sup-pliers began in May 200 7. Fir st of all,Avermann w ere aw arded t he contr act forthe supply of all pr oduction equipment.Immediately af terwards the contracts wereawarded for t he r einforcement equipment(Progress), the mixing plant equipment withbucket tr acks (Sk ako) and t he r ecyclingplant (Bibko) – to name just the main trades.The earthworks began immediately and the

Stationary manufacturing plant for facade and wallelements in Denmark

Ambercon A/S, 9530 Støvring, Denmark

Following many years of very limited investment within the pr ecast industry in Denmark, a remarkable new project was realised last year.The Danish family-o wned company Ambercon, from Støvring near Aalborg, erected a plant for top quality manufacturing in a r ecord timefrom planning to realisation. A total of 32 tilting tables in the newly er ected production halls can manufactur e up to 1500 m 2 of façade andwall elements daily – an order of magnitude that is unmatched anywhere in the world. At the same time, the higher demands with regard toquality, productivity and logistics at Ambercon (formerly S.E. Concrete) led to the necessity of replacing the existing decentralised capacitiesby a new production plant.

One of the largest tilting table production plants in Europe was taken into operation at theAmbercon company in Denmark

Overview of Ambercon’s new plant View of one of the two production halls

05b-Fertigteile_en.qxp:Layout 1 12.03.2009 12:08 Uhr Seite 202

new pr oduction facilities wit h w arehousearea and office building were erected. Boththe of fice and t he pr oduction halls hav ebeen designed to be br ight and fr iendly.One clear ly senses t hat people ar e mos timportant her e. Accor ding to Amber con’sManaging Director, Torben Enggaard, t hewell-being of every single employee is partof t he cor porate cultur e, wher eby team spirit is consciously pr omoted and bor dersbetween t he dif ferent pr ofessional gr oupsare blurred.

In all, jus t one single year passed betweenthe ground breaking and the opening cere-mony for t he concr ete pr ecast w orks on8/8/2008.

Concrete precast element production ontilting tables

The lar gest par t of t he equipment w as supplied b y A vermann Masc hinenfabrik,which is based in Osnabrüc k, Ger many.Use was specif ically made of A vermann’sextensive kno w-how and man y y ears ofexperience in the concrete precast industryhere.A wide variety of façade and wall elementsare concr eted on a total of 32 h ydraulic tilting tables, some of which are implementedas tandem groups. All tables are fitted withan edge form that is inf initely adjustable inheight as w ell as per manently ins talledvibration equipment, so t hat walls in t hick-nesses up to 500 mm can be manufacturedfrom SCC and normal concrete.

A total of 8 double-gir der gantr y cr anes,each wit h a load capacity of 20 metr ictons, are available for transporting the con-crete elements from the production area tothe adjacent, spacious w arehouse. Four ofthe cranes were supplied in a special versionfor bear ing t he concr eting equipment. Inorder to also be able to use t he cr anesalternatively for fur ther task s, t he concretedistributors ar e mer ely hook ed onto t hecrane and guided on t he tr olley of t hecrane via appropriate adaptors. The attach-ment and detac hment of t he concr etingequipment to and fr om a cr ane, includingthe automatic po wer supply line, tak es just2 minutes.The delivery of concrete inside the works isaccomplished via buc ket tr acks. Af ter t heoperator has ordered concrete, the correctmixture is manufactured in the mixing plantvia a cor responding contr oller and tr ans-

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Concrete disributor being coupled to thecrane

Radio controlled power trowel with 2 smoothing units

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ported by bucket track to the respective crane with the concrete dis-tributor. In this manner, concrete can be transferred at any place inthe hall, saving a gr eat deal of time. Eac h of t he concrete distribu-tors has a capacity of 2.5 m 3. The concr ete is deliv ered preciselyonto the tilting table via a dedicated lif ting unit in conjunction wit ha rotating unit. All functions are radio remote controlled.

Two power trowels accomplish t he smoothing of t he concrete ele-ment surfaces after concreting. Depending on the dimensions of theconcrete element, two smoothing units can be operated separatelyor in parallel on eac h machine. However, it r equires quite a bit ofintuition to determine the correct time for pre-smoothing (with a discwheel) and r epolishing. The e xperience and skills of t he operatorare called for here.

The power trowels are movable on the ground with longitudinal andtransverse chassis and can therefore be used at any time and in anyplace inside t he two production halls. So t hat no cables lie on t hefloor and in or der to eliminate t he associated r isks of damage, a clever cur rent collector sy stem w as de veloped especially forAmbercon. Thanks to this flexibility – the ability to access e very con-crete element at any time – waiting times in the production sequencecan be av oided. Since t he number of pr oducts t hat need to besmoothed is gr owing continuously , t his f lexibility of t he po wer trowels was an impor tant cr iterion. All functions ar e radio remotecontrolled here also.

Two additional cleaning/plotting/oiling mac hines (CPO) enablethe work preparation processes to be designed very effectively. Themachines ar e dr iven analogously on t he gr ound lik e t he po wer trowels. However, all procedures take place automatically here.After the concrete elements have been lifted off, the tilting tables aresubjected to high-quality mechanical cleaning. The residual concreteis removed from the table and the edge form by means of scrapersand cleaning brushes driven by electric motors and transported intothe residual rubble container at the end of the table. A vacuum unitinstalled on one of the machines removes fine-grained residual par-ticles (whic h accumulate in par ticular when w ashed concr ete ismanufactured) via an appropriate filter.The oiling of t he cleaned table sur faces/edge forms wit h releaseagent is accomplished r eliably and in t he desired intensity by spe -cial rotary nozzles. These nozzles practically never become blocked.Oiling can take place in dir ect combination wit h the cleaning pro-cess or as a separate process.

After cleaning (oiling), t he new concrete contours, cut-outs, built-incomponents and the like are plotted precisely on the table sur faceand t he concreting process s tarts again fr om t he beginning af tershuttering and installation of the reinforcement.

The mixing plant

The mixing plant w as planned and implemented jointly b yAmbercon and the Danish company Skako. Great importance wasthereby placed on high f lexibility, bot h in r elation to t he dif ferentrequirements in daily pr oduction and in t he long-term in relation tolater requirements.

The complete plant that Skako ultimately supplied and commissionedoffers a capacity of 1 25 m 3 concrete per hour . The main compo-nents of the plant are

· 24 aggregate silos for s toring the raw materials, each with acapacity of 60 m3.

· A special loading and dosing system for the aggregates withtwo movable trolleys, which ensure that all 24 different rawmaterials can be delivered to the three mixers and that two mixtures can always be produced simultaneously.

· Three Apollo countercurrent mixers, each of which can unloadthe concrete into two different concrete bucket tracks. In thismanner each mixer can serve the concrete requirements in oneof the two production halls.

· Two Conflex bucket tracks, which, with a speed of 4.5 m/s,ensure that the internal transport of concrete in the works doesnot represent a weak point in the production sequence. The bucket tracks take the concrete directly to the above-describedAvermann concrete distributors in the two production halls.

CPO machine in its home position

Distribution of aggregates to the 24 silos


AVERMANNMaschinenfabrik GmbH & Co. KG

Avermann Maschinenfabrik GmbH & Co. KG

Lengericher Landstraße 35 • 49078 Osnabrück • Germany • Phone +49 (0) 5405.5050 • Fax +49 (0) 5405.6441 • [email protected]

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Stationary production plant for the production

of façade and wall elements

circulation plant • shuttering • tilting tables • vibrating lines • pallets • special machines




The mixers are equipped wit h Visco Pr obemeasuring sy stems b y Con vi ApS, whic henable online measurement and monitoringof t he concr ete consis tency and viscosityduring the mixing process.

There are automatic cleaning pr ogrammesfor both the mixers and the bucket tracks, sothat various changes of dye during produc-tion do not pose an y pr oblem. A dosingsystem by Finke is installed at Ambercon fordosing the dyes. The o verall control of t hedosing and mixing plant is or ganised by aSkakomat 600 controller.

Reinforcement plant

The Progress company from Italy suppliedAmbercon wit h an M-Sy stem Ev olutionmesh welding plant for t he manufacture ofreinforcing meshes wit h various gr id sizes,dimensions and wir e diameters, as w ell asa mac hine for bending t he r einforcing mesh es. In this plant both the cross bars andthe longitudinal bars can be arranged with

complete f lexibility, without having to com-ply wit h specif ic gr id sizes. Not only t hat,particularly lar ge meshes wit h dimensionsof up to 6 m x 1 2 m can be manufactur edand can e ven be bent subsequently if r e -quired.

Production planning system

For the first time in stationary production ontilting tables, a contr ol system – LEIT2000by SAA - w as also used in t his project forproduction planning and t he control of t hemachines. The production planning system,with schedule adopted from the ERP systemand t he LEIT2000 pallet allocation, enab-les in t his case simple planning of t hetables, t he taking into account of edgeforms t hat have alr eady been cons tructedand the different element types and elementheights. Depending on t he size of t he ele-ment, t he production planning sy stem alsoprovides for two tilting tables to be coupledtogether in order to also be able to producelarger par ts. By means of t he pr intout of

component preparation lists and table allo-cation plans, t he employees in t he produc -tion halls ar e suppor ted ef fectively beforeand dur ing production. The w ork prepara -tion process is rounded off by the automatic,optimised gener ation of pr oduction datafor the fully automatic manufactur e of bentmeshes b y t he afor ementioned r einforce-ment machines and for the effective drivingof the SAA plotter controllers. The data con-nection to t he SAA controllers of t he CPOunits takes place via a wireless network thatcovers the entire hall area.

An o verview diagr am display s t he tableson the control centre and shows their coup-ling and allocation situations. The schedulesfor production are received and the statusesand manufactur ing times for t he individualconcrete elements are fed bac k to t he ERPsystem for processing via a modern databaseinterface. The CPO units equipped wit h theSAA-IPC controllers can be used f lexibly inthe hall and r eceive t he pre-planned datamatching the respective table from the con-

Transfer of the aggregates to the three inclined bucket elevators

Three Apollo mixers are used at Ambercon Cleaning station for the bucket tracks


www.cpi-worldwide.com CPI – Concrete Plant International – 2 | 2009 207


trol system. The LEIT2000 heating controllerwas also integr ated in t his plant. The hea-ting valves on the tables are activated accor-dingly via dif ferent heating pr ogrammesassigned to t he various element types andthe table heating cur ves are regulated viathe feedback from temperature sensors.

After the concrete worker gives the signal tostart, t he appr opriate heating pr ogrammecan be executed for each table. The actual

temperature curve is detected and the heatinput to t he placed elements is r ecordedgraphically.

Residual concrete recycling system

The Ger man compan y BIBK O® Umwelt -technik und Ber atung GmbH planned andimplemented a compr ehensive r ecyclingconcept for Amercon. Since the wall surfacesat Amber con can be manufactur ed as

wash ed concr ete or nor mal concr ete sur -faces depending on requirements, the recy-cling plant is divided into two areas:Area 1: BL ANDE ANL ÆG. The concr etemixing plant wit h a total of 3 concr etemixers is located here. Following the mixingprocess the concrete is transferred to one ofthe two bucket tracks and transported to thenecessary place in the works.Area 2: VASK FINISH HAL. The pos t-treat-ment of w ashed concr ete elements tak es

The Skakomat 600 controller organises all mixing processes Meshes with dimensions of up to 6 m x 12 m can be produced onthe mesh welding plant

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Layout of the reinforcement plant



place in this area using high pressure waterlances. Since the demands on the recyclingprocess or t he recycling plant r espectivelyare dif ferent in t he two areas, a separ ateconcept w as de veloped for eac h ar ea.However, these two systems are connectedto each other via an inter face.

BLANDE ANLÆGSince the largest quantities of r esidual con-crete accumulate in t he area of t he mixingplant, a recycling plant of type ComTec 20was pr ovided her e. Quantities of r esidualconcrete can be fed dir ectly to t he plantfrom the t hree mixers or t he bucket tracks.Washing water accumulating dur ing wash -ing of t he mixers and buc ket tracks is simi-larly fed directly to the recycling plant. Thecosts of tr eating r esidual concr ete ar e r e -duced significantly as a result.

The actual r ecycling or w ashing pr ocessthen takes place in the recycling plant, whe-reby aggregates > 0.2 mm (sand, gr avel)and w ater wit h cementitious f ines wit h agrain size < 0.2 mm ar e produced. Whils tthe aggr egates ar e disc harged via t hescrew con veyor attac hed to t he ComT ecrecycling plant, t he f ines and t he e xcesswater (r esidual w ater) r un into t he pumpsump via t he machine’s water overflow. In

this pump sump there is a pump that pumpsthe water with the f ines into agitation tank1. The agitator mounted in t his tank pr e-vents the sedimentation of t he fines, so thatthey are kept in suspension. Residual waterfrom t his tank is used on t he one hand towash the hopper t hat receives the washingwater and residual materials from the buckettrack and mix er washing process and, onthe other, to supply the Bibko material trans-port system with water.

In order to mak e residual water availablefor the actual mixing pr ocess with the mostuniform, specif ic pr operties possible, asecond agitation tank w as pr ovided inthese works. Whilst tank 1 serves to acceptthe une venly accumulating r esidual w aterand to buf fer it inter mediately, the residualwater is pumped into tank 2 af ter a certaintime, mostly in the morning on the followingday. Fluctuations in t he density of t he resi-dual water and differences in the degree ofchemical reaction (hydration) of the cementparticles during the course of daily produc-tion are compensated in this way. Followingthe transfer pumping process, agitation tank2 t hen contains r esidual water wit h a uni-form density and unifor m chemical proper-ties. The volume of t he agitation tank is dimen-sioned so t hat t he w ater r equirement forone day’ s pr oduction can be co vered b ythis tank . The adjus tment of t he concr eterecipes or compliance wit h t he prescribedspecifications is hence simplified considera-bly. Submer sible motor-dr iven pumps in -stalled directly in the agitation tank serve topump the residual water to the mixing plantor to the water weigher.

The density meter installed in agitation tank2 represents a further component for quality-assured concr ete pr oduction. The cur rentmeasured density v alue is made av ailableto t he plant contr oller continuously so t hatcorrections can be made if necessar y. Thequality of t he end pr oduct can hence be

Bent meshes are also possible at Ambercon

Table allocation with adjacent Gantt diagram. Heating programme window, temperaturecurve of an element

Plant diagram occupied by data




ensured at all times. In or der to mak e t hecleaning of concrete distributors possible, asecond pump sump w as pr ovided in t hefloor of t he factor y hall in t he BL ANDEANLÆG ar ea. This is par t of t he Bibk omaterial transport system and collects all ofthe material produced by the concrete dis-tributor cleaning process. Using water as atransport medium, t he r esidual mater ial isfed to the ComTec recycling plant for treat-ment. If t he above-described recycling pro-cess should r esult in an e xcess of w ater inthe BLANDE ANLÆG area, there is a possi-bility to pump this excess water into a multi-stage sedimentation tank. Sedimen tation ofthe f ines is desir ed in t his sedimentation

tank, so t hat t he las t c hamber of t he sedi-mentation tank contains clar ified w ater.This clar ified w ater ser ves t he r efilling ofagitation tank 1 , as w ashing water for t herecycling plant and, if necessar y, can beused directly in t he mixing plant as mixingwater.

VASK FINISH HALIn t he pos t-treatment of w ashed concr eteelements using high pr essure water lances,the concrete surface, which has not y et setdue to c hemical r etarders, is w ashed out.This uppermost layer, which is composed ofcementitious par ticles, sand and smallaggregates, is thereby loosened. This mate-

rial is collected in a gully toget her with thewater used. The material moves from thereinto t he Bibk o type R WS r ecycling plant,where t he actual r ecycling pr ocess t hentakes place.

Schematic overview of the BIBKO® recycling plant

Recycling plant, type ComTec, with pumpsump

Overview of the Bibko plant equipment inthe BLANDE ANLÆG area. Agitation tank 1 can be seen above, agitation tank 2 below

Gully for receiving the material Gully to RWS plant transfer area




Aggregates wit h par ticle sizes > 0.2 mm ar e disc harged via t heplant’s screw conveyor, whilst the excess water (residual water) withthe fines < 0.2 mm r uns into a pump sump via t he machine’s wateroutlet. In this pump sump there is a pump that pumps the water withthe fines into a multi-stage sedimentation tank. The pump for transferto the BLANDE ANLÆG plant section is ins talled in t he last cham-ber of t he tank alongside t he r insing pump for t he collection gullyfor the washed-out material. In addition to the aforementioned pro-cess for t he manufacture of w ashed concrete elements, t here aresome pr ocesses in t he VASK FINISH HAL ar ea in whic h acid isused. The w ater/acid mixture produced here is similar ly collectedand fed to the first chamber of t he sedimentation tank . This mixturethus leads to a r eduction in t he alkaline pH v alue of t he r esidualwater of 11 – 13.

Interface between the BLANDE ANLÆG and VASK FINISH HAL areasThe transfer pump or transfer pipe represents the interface betweenthe two systems. If t here is a lac k of water for concrete productionin the BLANDE ANLÆG area, it is refilled with water from the sedi-mentation tank in t he V ASK FINISH HAL ar ea. In t his w ay it isalways ensur ed t hat t here is suf ficient mixing w ater av ailable forconcrete production.

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RWS delivery (during installation) First concreting during the opening ceremony on 8/8/08 at 8.08 am

FURTHER INFORMATION

Ambercon A/SJuelstrupparken 23 · 9530 Støvring, DenmarkT + 45 70 216060 · F + 45 98 3 [email protected] · www.ambercon.dk

Avermann Maschinenfabrik GmbH & Co. KGLengericher Landstraße 35 · 49078 Osnabrück, Germany T +49 5405 5050 · F +49 5405 644 [email protected] · www.avermann.de

CPT A/SConcrete Plant TechnologyBygmestervej 8 · 5600 Faaborg, DenmarkT +45 6265 2070 · F +45 6265 [email protected] · www.cpt-as.dk

SAA Software Engineering GmbHSystem Analyse & AutomationGudrunstraße 184/4 9 · 1100 Wien, AustriaT +43 1 641424713 · F +43 1 [email protected] · www.saa.at

Progress Maschinen & Automation AGJulius-Durst-Straße 100 · 39042 Brixen, ItalyT +39 0472 979100 · F +39 0472 [email protected] · www.progress-m.com

Skako A/S Bygmestervej 2 · 5600 Faaborg, DenmarkT +45 6361 6100 · F +45 6361 6200 [email protected] · www.skako.com

Bibko Umwelttechnik & Beratung GmbHSteinbeisstraße 1-2 · 71717 Beilstein, Germany T +49 706292640 · F +49 [email protected] · www.bibko.com


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