Five German manufacturers have joined forces in a wetcast system partnership

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1 A vision of strategic cooperation becomes reality Five German manufacturers have joined forces in a wetcast system partnership When the proprietors of five German companies, Kniele Mischtechnik, Remei, Via Domo, WMW Industrieanlagen and Würschum, got to know each other better at the Intermat in Paris, they realised that a system partnership would be an important proposition for the wetcast industry worldwide. They were all unanimously persuaded that wetcast products have many advantages - provided production is maintained at cutting-edge level - when compared to the competition from the ceramic and natural stone industries. A system partnership would make it easier for manufacturers of wetcast products to conquer a significant share of the market and open up other markets. On top of this, standalone solutions are often needed for the production of wetcast products with international customers. Their local suppliers sometimes lack the appropriate expertise particularly in the areas of state-of-the-art design, modern concretes, new manufacturing or colouring and surface treatment technologies (coating, colouring and printing processes). In 2015, the five proprietors and family businesses got to grips for the first time with the vision of strategic cooperation in the wetcast sector. It rapidly became apparent that there is a recognisable renaissance of wetcast products in most markets. Although system manufacturers possess sophisticated knowledge when it comes to new investment in complete production lines and, depending on the task at hand, have often worked very closely with the five companies together, the fact remains that the majority of wetcast facilities in the world remain without full automation. In many areas, their systems are backwards and do not permit state-of-the-art wetcast products to be manufactured. Sand appearance with good attention to detail The decision was rapidly reached to create the possibility for customers throughout the world to be able to reliably access their combined expertise. Since that time, accurate market forecasting has been carried through on almost every continent. The opportunities currently arising for manufacturers of wetcast products are often quite surprising. Opportunities for wetcasters Wetcast 1,200 x 800 mm wall panels Wetcast technology makes great diversity possible in each product family. This, in turn, enables each concrete production facility to position itself uniquely on the market. Products such as block steps, large panels or specially structured paving blocks, and sizes up to e.g. 3 m edge length can be given any structure desired and thus pick up on the latest trends. Using good market analysis, wetcast products with exceptional designs can often generate comparatively higher yields than other products from the drycast area. 112 CPI Concrete Plant International

2 The many innovations of the five partners as well as their state-of-the art technology can place producers of concrete goods in a position whereby they can appreciably increase their weight on the market. Crucial factors in this are concrete quality, colouration and its durability, surface treatment and, of course, design. The minimum investment for a wetcast system with any substantial output is normally considerably less than it is for complete drycast plants. Markets can be built up carefully without having to cope with too great a cost for capital. In the meantime, plant manufacturers for wetcast products can be found who guarantee the same daily output performance (in this case fully automated) as that of typical drycast production facilities. Prototypes provide insights into potential sales successes Using a rapid prototype stage (manufacturing initial prototypes), several products can be developed simultaneously and introduced to existing customers in small batches from initial test moulds. In such cases, manufacturers of wetcast products incur only relatively minor expenses. Great product diversity can be generated for test markets with the aim of precisely analysing the potential of a new product. This substantially fosters sales opportunities and hence sales successes. The selection of concrete types (with regard to a product's thickness and strength but also mixing technique), colouration (type of colours and dosing strategy) and a striking design are the focal points in this success besides details concerning corners and edges. Special surface coatings and ageing tests should be envisaged right from the beginning. At the same time, a precise dosing technique for the concrete enables production tolerances to be maintained. This means that no excessive fluctuations occur in product dimensions and that sharp-edged products can be installed very precisely without their edges "turning up". State-of-the-art measuring technology plays a major role in quality assurance. Accurate weighing devices etc. are very important with the concrete composition in particular but also with the colouring process and filling the moulds. Enhancing existing wetcast systems Any improvements to existing wetcast systems can be covered by at least one of the five partner companies. This means that the concrete manufacturer receives cutting-edge technology coupled with the commitment and good proximity to customers that most mediumsized German companies can be proud of. Manufacturers of concrete products in many countries are unaware of all of today's technological possibilities - not to mention being able to exploit them - perhaps due to a lack of suitable suppliers within geographical proximity or due to company size. Cooperation with the five partner companies should ensure that wetcasters are always satisfactorily informed about the latest cutting-edge solutions, technologies or design possibilities. Each individual partner company possesses many years of experience and global expertise. This means that there is no chance of wetcast product manufacturers receiving untried technologies, colours, concrete admixtures, mould configurations or materials. CPI Concrete Plant International

3 Good attention to detail with wetcast products 890 x 250 mm wooden board Accurate assessment of each assignment at a concrete manufacturer ensures that no unsuitable standard solutions are offered. The manufacturer will always receive a solution proposal worked out specifically for his company. All five cooperating companies meet this requirement. Each of the five partner companies possesses knowledge of the international market. This enables all discussions to take place in terms of subsequent success on the market. A great variety of projects provides both indications of apparent trends and forecasting possibilities concerning the effi- YOUR WETCAST SPECIALISTS

4 Typical challenges for wetcasters Many recurring problems have been shown up when analysing the situation in concrete production facilities. The challenges for today's wetcast manufacturers are listed in the following: Installed wetcast slabs this example is sand shale (Silver Creek Stoneworks) ciency of the intended optimisation or investment. Absolute discretion is also part of all company philosophies. Networking amongst the five partner companies also always provides each customer with access to the diverse offers and cuttingedge possibilities of the other partners. - Unsatisfactory mixing techniques and concrete recipes result in poor strengths and fluctuating quality with high complaint rates as a consequence. - Valuable time is lost through emptying the mixer inefficiently and by complicated colour or mix changeovers. Expensive setup times occur. - A lack of colour diversity (inadequate equipment) or even poor colouration (often coupled with low resistance to ageing) increases complaint rates. Inaccurate dosing of colours and concrete admixtures prevents state-of-the-art wetcast products from being produced in uniform quality. - Non-existent surface protection leads to rapid ageing with a product, in particular its surface. - Concrete recipes are hardly ever checked for any optimisation potential since relevant specialists or specialised companies for wetcast products are almost unknown. Modern types of concrete are rarely utilised not least because the system quality does not permit precise mixtures and dosing. - Filling a mould or correcting filling levels manually leads repeatedly to fluctuations in product dimensions and large reject quotas. - If not harmonised with the concrete type and production conditions, the type of release agent and its application can cause difficulties in demoulding and stains on the products. - Many designs are not (no longer) suitable for today's markets. In addition is the fact that e.g. thermoformed moulds possess only weak contours and generate designs with little appeal. - The trend to larger formats has brought many systems to their limits so that products with promising futures cannot be produced. OUR COOPERATION YOUR GAIN Benefit from our many years of experience in all areas of wetcast production! Contact: Matthias Rimmele info@viadomo.com Phone:

5 - can have a striking effect by means of interesting colourations or imprints. (Würschum, Remei) - can be supplemented or modified at short call by rapid prototyping. Product families can be created at short notice in this way. - also include slabs for specific projects up to sizes of 2-3 m, which have only up to now exhibited the non-structured surface of formwork boards. State-ofthe-art structuring today makes e.g. a fine rough surface possible. - can achieve outstanding strength and durability. - make a lasting impression due to their exceptional quality comprised of their dimensional accuracy (e.g. precise concrete batching by WMW) as well as the durability of their surfaces and colouration. - can also be produced in small batches without having to accept an excessive loss in output from the system. In this case, crucial factors are colour changeover rapidity (Würschum) and mixing changes (Kniele). - are the visible face of a concrete manufacturer giving proof of his expertise in design. - are also perfectly designed and shaped in the edge area. Splendid surfaces exactly according to specification look impressive and create just the right atmosphere. This strategic cooperation can be of great importance for many wetcasters. The partners see themselves as generators of ideas and suppliers of the highest quality standards for the international market. Each stage of production, each aspect of a wetcast production line and wetcast product development can be accompanied by at least one partner at the latest cutting-edge level. Other German manufacturers of construction components and materials also play an important background role. An overview of specialised areas The five proprietors and family businesses of the Wetcast System Partners: (f. l. t. r) Matthias Goldschmidt (Remei), Hubert Würschum (Würschum), Jürgen Wizemann (WMW), Matthias Rimmele (Via Domo), Heribert Wilhelm (WMW), Harald und Alexander Kniele (Kniele) Integrated and holistic offers and solutions for customers Their close cooperation gives rise to integrated offers, which go far beyond pure plant construction. Each company involved acts as an independent entity. Each of the partners knows the capabilities of the others so that any contacts necessary can be made at an early stage and, for example, preparatory trials be initiated. This means that improvements can be carried out on time particularly in respect of concrete testing, colour processing or mix quality. End product attractiveness always in focus The attractiveness of an end product always remains the focal point of the individual partner companies. State-of-the-art wetcast products in cooperation with the wetcast partner companies - live from their design in conjunction with contemporary sizes and dimensions (Via Domo) - are able to be impressively "thin" by using high-class concretes right up to UHPC and thus compete effectively against ceramic products. (Remei) Kniele Mischtechnik Innovative, patented mixing technology (KKM conical mixers and complete mixing systems) for all types of concrete and other mixing materials. Partial batches (10-15%) are also possible with very rapid emptying and quick cleaning without residue. Remei Concrete optimisation and testing. Recipe creation. Colour processing and designing special surface properties. Protective systems for concrete surfaces; release and cleaning agents for wetcast moulds. Via Domo Exclusive design, prototyping and utilisation of premium materials for wetcast moulds. Polyurethane moulds up to approximately 3 m in length. Special reinforcement to maintain dimensional accuracy. Structure formers made from special hybrid materials such as meshes or inlays for precast products. Individual CAD-based prototyping. WMW Industrieanlagen Dosing/filling units for all types of concrete (weight, volume, time). Concrete spreading with differing discharge systems. Bucket conveyor belts, vertical stations, floor conveying vehicles and turn-key, ready-mix concrete facilities. Würschum Dosing systems and filling machines: colouring dosing for powder, granules and liquid colours. High precision dosing of mixed colours. Versatile specifically customised concrete admixture dosing. Manufacturer of weighing systems, dosing cylinder and pumps. 116 CPI Concrete Plant International

6 FURTHER INFORMATION KNIELE Baumaschinen GmbH Gemeindebeunden 6 D Bad Buchau, Germany T F info@kniele.de REMEI Blomberg GmbH & Co. KG Industriestraße Blomberg, Germany T F info@remei.de BCR Building Components Rimmele GmbH & Co. KG Röntgenstraße Ehingen, Germany T F info@viadomo.com WMW Industrieanlagen GmbH Tobelacker Fronreute-Baienbach, Germany T F info@wmw-industrie.de Würschum GmbH Hedelfinger Straße Ostfildern, Germany T F info@wuerschum.com CPI Concrete Plant International