Automatic, fully hydraulic, efficient: Hungarian Limelog Group expands stationary production of precast concrete parts
Since 2009, the Hungarian Limelog Group has specialised in the transport of high-quality building materials, grain and oversized machines and precast concrete parts inside and outside of Hungary. Since 2011, the company has also been extremely successful in producing reinforced concrete columns and beams. With KOMBISTEP stair formwork and high-performance tilting tables from Vollert's special portfolio, the company is now expanding its stationary precast concrete production.
Fourth sheet metal blanks high-bay warehouse for automobile production
Vollert erects a new material flow system with high-bay warehouse. It is already the fourth warehouse of the intralogistics specialist at the Mercedes-Benz press shop in Bremen. At the same time, Vollert increased the overall speed of the existing intralogistics processes.
Just-in-time precast floor slabs for the Belgian housing industry
The Belgian building materials specialist Daerden is expanding its capacity in the production of serially prefabricated semi-finished concrete parts. Just-in-time within 24 hours, it will in future be possible to supply its customers in the booming Belgian housing industry with floor slabs. Automated processes and Vollert technology make this possible.
Loading gravel fully automatically and environmentally friendly
In the quarry of the French building materials specialist Eqiom in the Bar-sur-Aube district, an energy-efficient fully automatic loading station ensures economical processes. For loading gravel, the wagons are constantly pulled through the filling station by an electrically operated KR 100 shunting robot.
Aluminium profiles for e-mobility in highest quality
Hammerer Aluminium Industries (HAI) is investing in a high-end production line at its Austrian site in Ranshofen. The aim is to produce aluminium profiles of the highest quality for the future topic of e-mobility. With an automatic crane and a fully automated buffer store, the SPS Group and Vollert ensure damage-free material flow between the existing and extended production lines. From planning to commissioning, the intralogistics specialists needed only 12 months.
Modular bathrooms efficiently and variable produced
Finnish building materials specialist Rakennusbetoni- ja Elementti expands its capacities in production of serially pre-fabricated bathroom modules. High-performance room mould by concrete specialist Vollert ensure high-quality surfaces and watertight room cells. The bathroom installation takes place very quickly, since the electrical and sanitary devices are already pre-installed.
Earthquake-resistant and made to measure: New method for producing prestressed hollow-core slabs shown for the first time at bauma 2019
At bauma 2019 in Munich from 8 to 14 April (hall B1, stand 311), Vollert will be presenting the latest machine concepts for modern precast concrete production. The centerpiece of exhibits is an innovative manufacturing process for prestressed, earthquake-resistant, hollow-core slabs. In addition, visitors will be able to immerse themselves on the spot in 360° virtual tours of current plant projects in Europe and Asia and learn more about the latest trends in production control systems.
3D printing technology inspiring Weinsberg students
3D printers have become indispensable in industry, model making and research. They allow for creating models, samples, proto-types, tools and end products layer by layer in the shortest possi-ble time. The students of the Justinus-Kerner Gymnasium in Weinsberg recently started performing three-dimensional experi-ments while gathering important skills in the new technology.
Uzbek DSK Binokor develops earthquake-proof construction system for more living space
Contemporary architecture defines the cityscape of Tashkent today. Construction boom and the demand for new housing continue unabated. However, Uzbekistan is located within a zone of high seismic activity and thus, earthquake safety is key here. DSK Binokor has recently developed a novel construction system and with it, innovative architecture for buildings becomes feasible.
Truck trailers are useful, but also big and heavy. This does not make their transport in the paint shop easy. Giga Coating GmbH recently built a completely new surface treatment plant in Twist. Here, up to 15.7 m long and 9 t heavy large parts are not only coated, but also blasted, dipped, swiveled and heat treated in hanging furnaces. The automated circulation principle creates capacities for up to 100 trailers and special parts per day in two construction stages.
The Oschatz concrete plant relies on robot technology
Forms, colours and surfaces become more and more modern; architecture turns increasingly diverse. At the same time, the capacities needed for building projects increase and the cost pressure is rising. The machine technology in precast concrete production must follow this trend. Modernisation is key in the Oschatz concrete plant.
Vollert currently delivers a total of 11 fully automated cranes to the mega rolling plant project of the Chinese Zhongwang Group. The manipulators link area storages, furnaces, warm and cold rolling, and transport up to 33 t of heavy ingots and coils with a four-fold step speed (4 m/s). For the LogiMAT 2019, the intralogistics specialist presents these and other special crane systems for loads of up to 100 tonnes.
For its new factory, Benninghoven, specialists in the construction of asphalt mixing plants up to 50 m in height and a member of the Wirtgen Group, is investing in a new double-track suspension system from Vollert for the overhead surface treatment of large parts. The special drive concept allows the overhead and flexible transport of up to 22 ton heavy parts, while at the same time enabling the energy-efficient separation of transport and furnace steel structures. Besides Benninghoven, in the company group Wirtgen and Kleemann are already using the proven Vollert technology.
James Hardie, a pioneer in fiber cement, is breaking the mold in the US with a new fully automated production line for facade siding. The integrated concept of heavy-duty expert Vollert includes in-plant transport, an air-conditioned, 100 m long high-bay warehouse, transfer tables, manipulators and automatically clocked autoclave trains. Tons of facade boards are loaded and unloaded within minutes. Automation accelerates the pace, reduces waste and saves space.
Tip and go: Loading by the cargo specialist Innofreight with shunting technology from Vollert
Innofreight Solutions GmbH from Austria has developed an innovative unloading station for the paper and packaging specialist, Mondi. As with voestalpine in Donawitz and at the Chvaletice power plant, Vollert's robust and energy-efficient shunting technology ensures reliable processes.
Industrial pre-production of TERIVA floor beams and slabs in Poland
The Polish building materials manufacturer Uciechowski will in future be producing floor beams and slabs on an industrial scale using the TERIVA building system. Whereas manufacturing was previously purely stationary, it is now based on the latest technology of the concrete plant specialist Vollert. 50 shuttering pallets are transported in the circulation system, known up to now only in modern precast concrete plants.
Weld, paint and fit wagons and trailers in one line
The Brazilian manufacturer Randon has built a 500m long combined welding, painting and assembly line for trailers and railway wagons in the state of São Paolo. Vollert has developed a heavy-duty material flow concept consisting of 13 combined rope conveyor drives, two moving distribution transfer platforms and the control system for the individually timed forward feed.
High speed production buffer for 3,000 tons of steel wire coils
Vollert erected for Saarstahl AG a new fully automatic high-bay warehouse for up to 665 steel wire coils at the Neunkirchen plant. In addition to the high cycle time of just 190 seconds per double cycle, the heavy-duty engineers also realized the handling of bundles weighing up to 4.5 tons directly from the stacker crane to the lift truck and on to the truck loading.
Chinese Baoye Group continues to invest in precast concrete production
The Chinese Baoye Group has built yet another precast concrete plant in Quzhou, 800 km southwest of Shanghai. Baoye will produce double walls and floor slabs of up to 700,000 square meters per year for mega-residential projects. At the heart is the latest plant technology from Vollert, a concrete plant specialist, while the focus is put on China’s hot topics, resource efficiency and environmental protection and prefab architecture as a sustainable building system.
Neuman Aluminum modernized their material flows in the extrusion plant in Marktl, Austria, during the Christmas holidays. At the core is a new automatic crane system by Vollert with 21 interchangeable cycles for loads of up to 3 tons. It replaces two existing transport cranes and is one of the fastest automatic cranes ever used in the extrusion industry.
Large-part painting systems designed around the corner
For LEWA as a special pump manufacturer and HAMM as a manufacturer of rollers for road construction and earthworks, Vollert developed and installed new floor-guided and overhead material flow systems for surface coating of parts weighing up to 12 tons. While high cycle times are crucial at HAMM, at LEWA for the first-time workpieces weighing tons travel 90° around the corner and thus enable an extremely compact system layout.
Brazilian MARNA Pré-fabricados modernises stair production
The Brazilian MARNA Pré-fabricados Group has continuously concentrated on precast element architecture since 2008. The stair production has now been extensively modernized with a VARIOSTEP stair mould 170-17 from Vollert's special product range.
bétons feidt creates special architecture in concrete
Precast architecture is modern and different. Numerous building projects worldwide prove that. It now has very little to do with standards and norms. One of the long-standing leaders among the manufacturers of such precast elements is the concrete specialist bétons feidt from Luxembourg. Vollert technology plays a big part in this.
Nuspl Schalungsbau and Vollert Anlagenbau will pool their expertise much more in the future. Nuspl Schalungsbau GmbH + Co. KG, part of the Vollert Group since 2012, has been fully integrated into the Vollert Anlagenbau GmbH as of October 1, 2017, including the complete range of formwork products. In the near future also customer care, development and production will be housed under one roof at the headquarters of Vollert in Weinsberg.
Experience says otherwise - and yet, here is the fact: The 1,000-meter-long special ropes used in the two shunting systems with standard gauge pusher trucks from Vollert at the Russian refinery Slavneft-Yanos have done their job for 13 years - in spite of almost non-stop use and extreme temperature differences.
With the newly developed VLEX road-rail robot, Vollert offers the finest solution for light shunting operation up to 300 tons: Extremely compact and flexible, battery-driven and exhaust-free, the small VLEX is suitable to change tracks fast in a very confined space.
With a retrofit and thorough automation concept, MKM Mansfelder Kupfer und Messing GmbH in Hettstedt is streamlining its internal storage logistics. The special feature: A floor-free, ceiling-guided warehouse handling machine with telescopic column takes care of moving the wire coils, which weigh up to 6 metric tons (6.6 US tons), in and out of storage. Instead of an exchange, the almost 20-year-old device was overhauled and modernized so that it now takes over the processes fully automatically. The most modern control software ensures fluid, rounded and thus low-strain motion cycles.
Manufacturers of precast concrete elements increase product quality and system productivity through modernization investments
The system technology of many precast concrete element factories comes from the 1990s and is based on the standard of knowledge of the then relatively young field of prefabricated elements. Today, rising cost pressure and ever more versatile prefabricated element architecture with regard to forms, colors and surface qualities require new technology standards. The manufacturers of precast concrete elements are reacting to this demand and investing in machine technology and higher automation.
TRIMET Aluminium SE uses a new and so far unique in the world technique for the cooling of green anodes in its Hamburg factory: The pilot plant reduces the resource usage and dispenses with active cooling by water. Instead TRIMET relies on cooling by natural convection with outside air – and this with success.
New type of concrete sleeper for Baku's Metro lines
The plant specialist Vollert is implementing a new concrete sleeper production plant in Baku. In conjunction with this, apart from development services for the modern plant technology, the company is also providing extensive engineering services for the planning and realisation of the track system for the Azerbaijanian capital's underground railway. The Weinsberg-based mechanical engineering company is offering this service as engineering partner and general contractor.
Earthquake-proof construction systems on a precast basis significantly change the face of Uzbekistan
The face of Tashkent as the capital of Uzbekistan is subject to constant change. The city with more than 2 million inhabitants has been the political, cultural as well as the economic center of the former Soviet state since the 1990s. New residential buildings are constructed as quickly as modern shopping malls, hospitals and universities – those projects are subject to precast architecture, also due to their high earthquake resistance.
Bangalore’s Sobha Ltd. is among the fastest-growing backward integrated property developers in India with more than 360 construction projects completed. In 2015 Sobha set the next milestone in the company‘s history with the installation of the largest onsite precast plant in India in Bangalore with German technology by Vollert. The residential construction project Sobha Dream Acres is now the first construction project implemented that is fully based on prefabricated elements.
Shanghai Baoye relies on state-of-the-art precast construction technology
Precast construction technology has a long tradition of nearly 60 years in China. The boom was brought to a sudden stop in the 1990s, however, by a lack of state subsidies and components of inferior quality. This has changed today, with state-of-the-art precast architecture, the importance of environmental and resource protection, as well as new industrialised manufacturing methods. Chinese builders such as Shanghai Baoye group invest in state-of-the-art machinery and plant technology.
Belgian Cordeel Group becomes a key player of the European construction industry
Belgian Cordeel Group is a nationally leading construction company. The general contractor implements diverse building projects, from exclusive apartment facilities to logistics or industrial parks, modern shopping malls, hospitals, schools or infrastructure projects such as bridges. With the new precast concrete plant in Temse, Cordeel has finally become one of the large key players in Europe.
BauMax is developing a precast construction system for residential buildings in Chile
A newly developed precast construction system has now conquered Chile. In addition to seismic stability, it offers shorter construction times and higher building quality. Serial production of the new house type has started.
Low-loader manufacturer Faymonville dispatches components weighing up to 12 tons through its overhead painting plant in Luxembourg. The material flow concept also comes from a heavy load expert – from Vollert based in Weinsberg. The control system supports automatic operation as well as the manual transportation of parts. Friction wheels facilitate the space-saving plant layout.
Twins usually come in pairs: Thai SCG Group invests in modern precast concrete production
Since the 1970s, Thailand has experienced a rapid economic boom. This path was cut in a much shorter period of time than in other countries like Taiwan or South Korea. And in spite of current political instability, the demand for real estate in the cities remains uninterrupted. Furthermore, rural regions are also being increasingly utilised for low-cost living space. The national construction industry in Thailand has recognised this and continues to invest in the most modern technology for precast concrete production, including the SCG Group.
Precise heavy-load crane systems for ingots and coils, etc.
Whether hot, sensitive, uneven or weighing several tonnes - the automatic cranes in the new mega-rolling plants of the Zhongwang Group in Tianjin now move slabs and coils securely and around four times as fast as conventional systems. The technology, control and stores management for this has all come from the intralogistics experts Vollert in the south of Germany.
Precast concrete elements for Brazil’s construction industry
In future M3SP will produce up to 400,000 m² of solid concrete elements annually for the Brazilian market. One of the most modern precast plants in South America has been built for this in Cotia near São Paulo.
Thailand uses railway sleepers made of steel reinforced concrete for large-scale railway projects
Thailand has undergone a rapid economic boom since the 1970s. This path was traversed in a very much shorter period than, for example, in Taiwan or South Korea. Despite the current political instability and only 5% growth, the expansion of the industrial sector continues to be promoted; alongside tourism it accounts for 45% of the gross national product. Therefore, investment is being made in the development of the infrastructure. Several large railway construction projects are planned in the next 5 years in order to network Thailand’s big cities with the less developed rural areas. The STRABAG Group will supply a major part of the equipment for the rail network.
From the 3D building model to the production-stage precast concrete element: know-how and plant technology for Kazakhstan’s building industry
With an area of 2,724,900 km², Kazakhstan is the ninth-largest country in the world. As a developing country with average economic growth of nearly 10 % (since 1999), Kazakhstan excels in central Asia and leaves most other countries in this region far behind. The economic development is also stimulating the building boom. The demand for property in the large cities has not let up in the last ten years and continues to develop progressively. This is simultaneously accompanied by the cost-effective production of precast concrete elements.
With average temperatures of between 20 and 30 °C as well as fantastic beaches and diving areas, New Caledonia - the French archipelago in the South Pacific, situated 2,000 km east of the Australian coast - is one of the most popular holiday destinations worldwide. The 250,000 inhabitants live predominantly from tourism and the mining industry. The focus is placed on precast construction for the development of new buildings for residential areas and public institutions as well as new tourism projects. Architecturally appealing houses and multi-storey residential buildings are to be built as well as hospitals, schools, complete hotel complexes and industrial workshops. The precast plant of the New Caledonian LBDP Group, completed in April 2014, will in future produce floor slabs and double and sandwich walls as well as beams and columns for hall buildings.
Prestressed concrete sleepers for the American continent
High-speed routes exceeding 200 km/h and higher axle loads place an enormous amount of stress on the permanent ways of railway lines. Prestressed concrete sleepers for track systems are therefore increasingly replacing the steel or timber sleepers in rail networks. They are more durable, require less maintenance and are also environmentally friendlier since no creosote is required for impregnation. In order to cover the rising demands of the industry and the public authorities, building material manufacturers and building contractors are increasingly investing in modern production plants. The GIC Group is also doing so at its headquarters in Monterrey, Mexico.
High-bay and automated intralogistics system speeds up production for Aleris
Aleris International, Inc. plans to boost production capacity in Duffel, Belgium with a new Sexto mill. To ensure smooth operation, Vollert Anlagenbau from Weinsberg will provide a fully-automated intralogistics system with high-bay warehouse. Up to 32 coils with a maximum unit weight of 25 tons are moved in and out of the warehouse each hour.
In the new Siemens AG Austria coating center, metros and passenger carriages are automatically transported via a central transport system to the individual coating treatment booths. The transfer table allows for flexible arrangement of individual processing stations and offers the highest level of safety for crossing passenger traffic.
Up and away – Continental exchanges 75 meters of test track in a matter of minutes
Anything but small, the exchangeable pavement cassettes used in the world's first fully climatized indoor tire testing facility from Continental weigh more than 100 tons and measure 75 meters in length. The facility allows the tire manufacturer to conduct 100,000 dry and wet brake tests per year using up to five different sections of test pavement. Vollert developed the system that quickly changes the cassettes.
The Indian construction company Precast India Infrastructures Pvt Ltd. has responded to the high demand from the local construction industry for solid walls, solid floors and floor slabs by opening a new production plant. The state-of-the-art pallet circulation system in the city of Pune in Western India is designed for an hourly production capacity of up to 120 m² precast concrete parts. The production technology was supplied by the plant engineering specialist Vollert Anlagenbau from Germany. The plant has been planned to cater for further expansion at a later date, with the addition of further product lines such as double walls.
Fully automatic coil transport in Hydro aluminium mill
Hydro Aluminium Rolled Products GmbH has commissioned Vollert Anlagenbau to modernise its existing plant in Grevenbroich by designing an end-to-end intralogistics system that automatically loads and unloads lorries, stores up to 4,000 tons of aluminium coil, and uses trolleys with inductive power transfer.
Battery-powered, emissions-free transporters that operate without a driver are being used for the first time at HHLA Container Terminal Altenwerder (CTA). To quickly and frequently exchange the batteries in the onboard battery boxes, which can weigh up to 12 tons, Vollert Anlagenbau developed a fully automated handling station in close collaboration with Gottwald Port Technology GmbH.
Automatic long items and small parts storage for aluminum profile systems
heroal's new high-bay warehouse has the capacity for 10,000 long items and 7,000 euro pallets. A centrally controlled intralogistics system from Vollert ensures a smooth material flow between infeed and outfeed.
From 0 to 450.000 pre-stressed concrete sleepers: Inkol Insaat starts operating state-of-the-art production plant
One of the most advanced mould circuits for railway sleepers has initiated its operations in the Turkish Afyon. In the future Inkol Insaat will produce 450.000 pre-stressed concrete sleepers per year in a 2-shift operation. Vollert Anlagenbau, the specialist in precast concrete works, has been responsible for the know-how and the technology in developing the plant within six months after the contract was signed.
Vollert manufactures transfer cars for coating 13,000 carriages annually
The Tikhvin Railway Car Building Plant (TVSZ) is currently building a state-of-the-art plant for assembling open- and closed-top freight carriages in the Russian town of Tikhvin. To this end, Vollert Anlagenbau from Weinsberg was commissioned to manufacture four transfer cars with payloads of between 70 and 100 tons. A heated enclosure installed on top of the cars provides optimal protection against the elements.
Vollert Anlagenbau develops a 260-ton automatic crane for Vallourec & Mannesmann Tubes
A 260-ton automatic crane is the latest highlight in Vollert's intralogistics programme for heavy-duty applications. Capable of travelling up to 2.7 m/s and featuring a 44-m span width, the crane has a 35-ton payload and will be used to transport heavy objects on site at the customer's steel tube plant in Düsseldorf-Rath. The world's market leader manufacturers steel tubes for applications in oil and gas fields, power plants, and the chemical and petrochemical industry.
Friction wheels transport large gearboxes for painting
The SEW-EURODRIVE drive automation system by Bruchsal relies on a simple, flexible material flow system by Vollert Anlagenbau for coating large gearbox units weighing up to 3.5 tons. It combines the advantages of Power&Free systems and requires significantly fewer system components. Nevertheless, comparably high cycle times are possible.
Liebherr breaks new ground with a new large-scale paint shop for hydraulic excavators: The components, weighing up to twenty tons, are conveyed through the system on a guided track while freely suspended. A special drive solution ensures optimal protection against explosion in the painting and drying booths.
F. X. Meiller Fahrzeug- & Maschinenfabrik commissioned its new facilities for coating large items in early July. Two 70 m-long painting tunnels installed in parallel offer space for 14 stations and can each take up to 12 items weighing 8 tons apiece. Two chain conveyor systems from Vollert provide the required pulling force.
At Wirtgen GmbH in Windhagen, world market leaders in the field of cold milling for road construction, components weighing up to 30 tons are freely suspended. The steel construction of the 230 °C furnaces is completely separated from the transport steel construction to protect against energy losses. This is made possible by special drive technology. Even with the heaviest loads, it allows for gap bridging of 70 cm. In addition, it is wear and explosion proof. The system was designed by Vollert Anlagenbau in Weinsberg.
Facility for loading 10,000 beverage crates per hour
South Korean bottler Login Beverage commissioned Vollert Anlagenbau to deliver a semi-automatic loading station for trucks. The special-purpose loader can move up to 180 pallets carrying 10,000 beverage crates per hour and does the work of three forklift trucks. Twenty different types of truck are serviced.
Custom manipulator with three synchronous hoisters lifts aluminium profiles up to 18 metres in length
Schletter GmbH, the largest supplier of solar mounting systems in Europe, has commissioned Vollert Anlagenbau to design a custom manipulator with three hoisters that can work together or separately to lift profiles weighing up to 9 tons with a maximum length of 18 metres. The manipulator will be used in a new buffer warehouse and is extremely compact to ensure optimal utilisation of vertical space.
50 tons of explosion-protected parts painted while suspended
With a new painting plant, Liebherr is setting the standard in commercial vehicle construction. At the plant in Ehingen, parts from mobile and crawler cranes weighing up to 50 tons will be painted while suspended in mid-air. Vollert Anlagenbau from Weinsberg is developing the intralogistics for this. Wirtgen and SEW-EURODRIVE are just two of the companies also backing the new technology.
SSAB stores up to 6000 tons of steel in a high-bay warehouse
The steel manufacturer SSAB in Oxelösund produces steel plates in one minute tact cycle. The information which plate comes next for what customer is only available three minutes prior to the production exit, thus the intralogistics system must react with appropriate speed. The solution supplied by the Vollert plant engineering company from Weinsberg, is achieved by conversion from a surface warehouse to a high-bay warehouse system with two MEGA AS/RS that enable short cycle times despite loads of tonnages.
Earthquake-resistant: New high-bay warehouse from Xiashun holds 800 aluminium coils
Vollert Anlagenbau GmbH from Weinsberg, Germany, is developing an entire intralogistic system with a fully automated high-bay warehouse for Asia’s leading aluminium foil manufacturer. The contract from China, with a total volume of approximately thirteen million Euro, is no easy task: The warehouse, which has a capacity of around 14,000 tons, is located in one of the most dangerous earthquake regions in the world and must withstand seismic shocks which measure up to 5 and 6 on the Richter scale. With the new production plant, Xiashun is in a position to manufacture litho material of the highest quality.
Two stacker cranes in a high-bay racking warehouse supplied by Vollert Anlagenbau of Weinsberg ensure a fresh supply of new cars every day at the new BMW Welt in Munich. The short-stay warehouse provides 284 storage positions on four levels and is located 12 metres deep down in the belly of the huge delivery hall. From here, the cars are moved fully automatically to the so-called Premiere Arena – the centrepiece of BMW Welt – for presentation and collection.
When others are running out of steam, the engineers at Vollert Anlagenbau are just getting into their stride, specialising in intralogistics systems for heavy goods – especially for the metalworking industry. For the aluminium extrusion works of apt Hiller for example, Vollert developed a fully automated intralogistics system which facilitates an end-to-end material flow from the extrusion works to the processing department and then on to the downstream anodising plant and newly constructed shipping warehouse. Major parts of the new system were installed and existing systems modernised and integrated while production was ongoing. As well as a higher handling capacity, the virtual warehouse of the transport control system allows optimum utilisation of the space offered by in-process stores, even with different sizes of transport basket.