Ceremonial opening of the pallet circulation plant in Shaoxing, China

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1 Avermann Maschinenfabrik GmbH & Co. KG, Osnabrück, Germany Ceremonial opening of the pallet circulation plant in Shaoxing, China As already briefly reported in issue 2/2013 of CPI, the German company Avermann was commissioned to supply a fully automatic pallet circulation plant for the manufacture of floor elements and double walls to the German-Chinese joint venture Baoye-Sievert in Shaoxing in the province of Zhejiang. In record time just eight months elapsed from the signing of the contract in December 2012 to the start of production in August 2013 the plant components were manufactured, delivered by sea, installed and commissioned. On 26 August this year the official opening of the plant took place in the presence of the top management from Baoye and Sievert AG. Lutz Pfleger, Avermann Maschinenfabrik GmbH & Co. KG, Germany Planning/building phase Residential and industrial construction in China is characterised by a complex, earthquake-proof building method, preferably executed with a framed construction with columns and beams made of steel reinforced concrete and bricked-up infills. Traditionally the structures are cast in situ directly on the building site and realised using a very large number of personnel. In the last two years, however, the industrialisation of the construction industry in China has attained increasing importance. On the one hand, the number of the cheap workers in the building industry (so-called migratory workers ) has fallen dramatically and, on the other, quality requirements have increased. Accordingly, the use of precast elements is being promoted by the state. To account for these increasing changes, the responsible people at the Baoye Sievert joint venture decided on the construction of a further plant for the industrial manufacture of lattice girder slabs and double walls at the headquarters of Baoye in Shaoxing in the province of Zhejiang. A major advantage in the planning was the possibility to fall back on the experience gained from the already existing plants at the Hefei site in the province of Anhui. In the summer 2012 various equipment manufacturers were contacted and their plant concepts were inspected and evaluated. As a result of the exploratory talks/negotiations, the Avermann company was awarded the contract for the supply of the pallet circulation plant. The package included their sub-suppliers Unitechnik for the process and circulation controller, including the master computer, and Ratec for the shuttering components. The CAD programming technology was purchased directly from Nemetschek; the mixing plant and reinforcement equipment was ordered from local Chinese manufacturers. The plant was newly built on a greenfield site. The building work with the required earthworks and foundations plus the construction of the hall proceeded extremely quickly, allowing the installation of the plant to commence in May and commissioning to take place on time in August. Plant concept with production equipment The plant is designed for a production capacity of 300,000 m² floor slabs and 100,000 m² double walls per year. It is planned to expand the production to up to 200,000 m² double walls per year at a later date. The hardening chamber area consists of four racks built on a steel platform with passages underneath. The storage capacity of the fully insulated hardening chamber was designed for 39 pallets. The hardening chamber is fed by an electro-hydraulic storage and retrieval machine which, like all the other circulating components, is optimised to the average cycle time of 12 minutes. The Official start-up of the plant by Professor Sievert (Sievert AG) and Mr. Pang (Baoye) Production hall with gantry crane for the outdoor store 186 CPI Concrete Plant International

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3 Avermann storage and retrieval machine is characterised by further advantages such as floor-level operation without a pit and the height-optimised storage method. Plant layout Hardening chamber area with storage and retrieval machine Preliminary demoulding of the pallets with the hardened concrete parts takes place immediately behind the storage and retrieval machine. The integrated magnets of the Ratec magnetic shuttering are released and sent directly for cleaning via a conveyor belt. Double walls are lifted off at the subsequent tilting station by means of a crane and transported to the outdoor store using two run-off trucks. The empty pallet subsequently drives through the pallet cleaner to a buffer station in front of the shuttering area and a transverse conveyor automatically transports it under the Avermann shuttering robot as soon as the latter is free. The robot is located inside the shuttering and parts store in order to save space and to keep the distances short and minimise the driving times. The shuttering robot takes care of all the shuttering work allowed by the grid as well as the plotting of elements that are not to be shuttered automatically. The shuttering itself is identified after the combined cleaning and oiling and transported into an active magazine at the front side of the pallet. The management of the active magazine is integrated into the Unitechnik robot controller and enables free and direct access to all shuttering compartments. All magnetic shuttering, if it is available in this magazine and required, is used on the current pallet to be shuttered. Missing shuttering elements are taken by the robot from the passive magazine located on the longitudinal side of the pallet. The shuttering is restacked from the active to the passive magazine only if the transverse transport at the end is occupied and no further shuttering transport would be possible. Unnecessary trips of the robot gantry are thus avoided, time is saved and wear is reduced. Special solutions were realised where the robot and the magazines are concerned. For example, the standard pro boxes (SPB 450) from Ratec are moved on a separate conveyor to the automatic area. The pro boxes are put in place by the shuttering robot in order to define door and window recesses and in particular also to specify the positions of special shuttering for the subsequent manual shuttering station. Demoulding area with tilting station and stop end cleaner Once the automatic shuttering processes have been completed, the pallet is moved out of the automatic area. Supplementary 188 CPI Concrete Plant International

4 Pallet cleaning Identification of the stop end formwork with active magazine Avermann shuttering robot CPI Concrete Plant International

5 Feed conveyor for magnets shuttering work is performed at the following two manual shuttering stations. From there the pallets go to three standard reinforcement stations and a workstation for special parts located outside the circulating line. In parallel to this production line a steel and lattice girder processing machine from a local Chinese manufacturer is located against the wall of the building. The bars and lattice girders requested and provided by the master computer can thus be installed directly in the pallets via short routes. Following a brief quality check, the shuttered and reinforced pallets are taken by transverse transfer conveyors to the concreting and compaction station. The concrete distributor with a bridge design is filled directly under the mixer and drives in a longitudinal direction over compaction station 1. The concrete distributor is operated manually, but is prepared for possible automatic operation at a later date. The vibrating compactor at the concreting station is responsible for the lattice girder slabs and the facing shells, while the neighbouring vibrating compactor is responsible for the double walls. The lattice girder slabs and the (1st) half shells are sent directly from the concreting and compaction station under the rack for placing into storage. On the way the floor slabs pass through the lowered roughening rakes in order to prepare the surface for the binding of the cast-in-situ concrete. The finished double wall is taken from the neighbouring second vibration compactor to the hardening rack on its own track. A third production line is responsible for the hardened first shells provided by the master computer. In order to avoid bottlenecks the passage under the rack is designed as a lifting overtaking station. On the return of the empty first shell pallet, it can be temporarily buffered in the lifting station so as not to hinder the feeding of the next first shell. After the tilting table machine has been supplied again, the empty pallet moves on for cleaning. On this third production line the pallets are taken up by the tilting table machine. Following the clamping of pallets and elements, the tilting table machine is ready to lower the first shell into the freshly concreted second shell in order to manufacture a new double wall. At the end of the production sequence the storage and retrieval machine is called into action once more. The freshly concreted elements are placed into storage for hardening, dry walls are taken to the demoulding area or first shells to the tilting table machine. The master computer as well as the circulation and robot controller were supplied and commissioned entirely by Unitechnik. The Example of use of the pro boxes Steel and lattice girder processing 190 CPI Concrete Plant International

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7 Concreting and compaction station control system controls both the plant logistics and the data transfer for production preparation. The individual production processes are defined in different work schedules and are firmly linked with the pallet at the shuttering robot station. The work schedules define the production sequence step by step and define the different paths of the pallets within production. The user-friendly control system allows the plant manager to intervene in the sequence at any time or to make changes, for example to the drying duration. Drawings for new wall types, such as the insulated double wall, can also be prepared by the production manager. The entire documentation of the production, with evaluations, tables and statistics, is of course available at any time. The CAD data are prepared once for the machine controller and transmitted automatically. Single sheet extracts with component outlines, the positions of the built-in parts and reinforcement for the manual work are printed at the same time. These accompany the pallet throughout the entire work process and contribute to a smooth execution, with corresponding quality assurance. One point that should not be underestimated is the complete remote maintenance of the controller. Errors that occur can be diagnosed and rectified over the Internet. Conclusions and outlook It is estimated that the demand for highquality precast concrete elements will be very high in the coming years. Justice was thus done to the joint market strategy of the Baoye-Sievert joint venture by the building of the new production facility in Shaoxing. Baoye, a building company with over 70,000 employees, and Sievert AG with its know-how form an ideal partnership for this. With the investment in this modern pallet circulation plant the joint venture has an efficient, fully automatic production facility at its disposal for the manufacture of lattice girder slabs and walls as well as special parts for both residential and industrial construction. Owing to very good co-operation Avermann was able to realise this project smoothly, on time and successfully together with the customer and Unitechnik. The Baoye-Sievert joint venture has thus added a further string to the bow of a successful company and will be able to face the market extremely competitively. Tilting table machine with 1st half shell 192 CPI Concrete Plant International

8 FURTHER INFORMATION Avermann Maschinenfabrik GmbH & Co. KG Lengericher Landstr Osnabrück, Germany T F info@avermann.de Baoye Sievert Concrete Precast Elements Co., Ltd. No. 889 Qunxian West Road, Keqiao Shaoxing,Zhejiang, P.R. China info@baoyegroup.com Sievert AG Mühleneschweg Osnabrück, Germany T F info@sievert-ag.de Unitechnik System GmbH Fritz-Kotz-Str. 14 Industriegebiet Bomig West Wiehl, Germany T F info@unitechnik.com Ratec GmbH Karlsruher Str Hockenheim, Germany T F info@ratec.org RELIABLE PROGRESS Nemetschek Engineering GmbH Stadionstraße Wals-Siezenheim, Austria T F info@nemetschek-engineering.com TRAILERS TO THE MAX FAYMONVILLE DISTRIBUTION AG Duarrefstrooss 19 I L-9990 WEISWAMPACH T: I F: sales@faymonville.com CPI Concrete Plant International