Newsletter-EBAWE_2017_ENG

ENG
NEWS
COMPANY
Gamuda Berhad
EMPLOYEES / TURNOVER
3.500 / 511,4 million euros
LOCATION
Petaling Jaya, Malaysia
START OF PRODUCTION
2016
TYPE OF PLANT
Turnkey plant
PRODUCTS
Solid walls and slabs
CAPACITY
Currently: 500.000 m 2 /year
Expansion: 1.000.000 m 2 /year
LEADING MALAY CONSTRUCTION COMPANY
RELIES ON PRECAST CONCRETE ELEMENTS
Leap from traditional methods to prefabricated construction method
The principles of quality, sustainability and efficient construction are central to Gamuda‘s
business. Consequently, the obvious next step for Malaysia‘s leading infrastructure and
land developer was to invest in modern technology for the manufacture of precast concrete
elements. In 2016 a new precast concrete plant began operation near Kuala Lumpur.
By opening this plant the company made the leap from traditional building methods to
construction in prefabricated concrete sections, a method with a promising future.
More than 2,000 residential units per year
Gamuda‘s aim was to acquire a turnkey plant to produce solid walls and slabs for
their own needs. This should drastically reduce construction times and guarantee
consistently high quality. They worked with EBAWE Anlagentechnik to implement a
concept for a carrousel system, which can be used to produce up to 1,000,000 m 2 of
wall and ceiling elements per year.
Efficiency through automation
Integrated software solutions, intelligent machine control systems, logistics systems
and robots ensure that the production process in the new plant runs at a highly
automated level. This minimises sources of error and at the same time improves rates
of production and quality.
The shuttering and de-shuttering, for instance, has been entirely taken over by
the Form Master shuttering and de-shuttering robot. The manufacture of made to
measure mesh also follows the efficiency principle. Rebar mesh is produced by a
M-System BlueMesh type mesh welding plant to individual specifications and then
placed automatically on the pallet. This, together with the VGA lattice girder welding
plant and the EBA S automatic stirrup bender, enables Gamuda to manufacture the
required made to measure mesh completely autonomously and just in time.
In the carrousel system the automatic concrete spreader ensures additional efficiency,
since it spreads fresh concrete with precision and at a steady rate. After compaction,
smoothing and curing the finished elements are removed and stored.
Individual precast concrete elements of the highest quality
A first project, the 20-storey Jade Hills residential complex has already been completed.
With the new carrousel system Gamuda now has the capacity to produce prefabricated
elements for all its many future projects totally in accordance with the company motto,
„Quality Beyond Aesthetics.“
The solid walls and slabs are used for in-house construction projects.
In the first phase of expansion the new site will produce precast
concrete elements for the construction of over 2,000 dwellings per year.

COMPANY
Geelen Beton
LOCATION
Wanssum, Netherlands
START OF PRODUCTION
2016
TYPE OF PLANT
New carrousel plant
BOOM IN PRIVATE
HOUSING CONSTRUCTION
Niels van der Hulst, Technical Director:
„The team understands our needs.“
Highly automated, standardised and flexible
The traditional Dutch precast concrete element producer, Geelen Beton, has for a long
time been concentrating on the production of elements for major infrastructure facilities
and the manufacturing of solid walls, lattice girder floors and insulated ceiling at its two
production sites. When, in the last few years, the trend for constructing with precast
concrete elements spread increasingly into the private house construction industry, the
company decided on a complete new build for the carrousel system in Wanssum.
Production was to be geared to present requirements: highly automated, standardised
and at the same time flexible.
Key role: fully automatic shuttering and combination system
The fully automatic shuttering and de-shuttering Form Master robots and the Infinity
Line ® combination system play a key role in this standardised and at the same time
flexible production process. Infinity Line ® makes it possible to combine different shutter
lengths to the best advantage and thus to reduce the number of shutters required to a
minimum. The entire carrousel plant is controlled by the ebos ® control system.
Geelen Beton has already worked successfully with Progress Maschinen & Automation
in the past. This latest project with EBAWE Anlagentechnik was also consistently rated
as successful: „I find working with the whole PROGRESS GROUP extremely simple
right from the start,“ comments the Technical Director, Niels van der Hulst. „The team
understands our needs and wishes and in addition they are totally familiar with the
production process and products.“
Infinity Line ® enables Geelen Beton to combine shutters of various lengths without using polystyrene extensions.
COMPANY
Prefaco NV/SA
LOCATION
Lebbeke, Belgium
START OF PRODUCTION
2016
TYPE OF PLANT
Modernised carrousel plant
CRH INVESTS IN PRECAST
CONCRETE ELEMENT PRODUCTION
High quality requirements – need for modernisation
With a wide range in its product portfolio Prefaco, a company in the CRH Structural
Concrete Belgium consortium, is one of the largest manufacturers of precast concrete
elements on the Belgian market. At a total of four production sites pre-stressed and
loosely reinforced lattice girder floors, double and solid walls and structural precast
concrete elements are manufactured. Prefaco is also the distributor for Calduran sand
lime bricks.
The Project Manager, Jean Pierre Van
Renterghem shows his satisfaction.
Automation package
The company has been able to achieve these goals by installing an automation
package, comprising a shuttering and de-shuttering Form Master robot, the Infinity
Line ® combination system and the ebos ® control system. „Thanks to Infinity Line ® our
elements now have perfect outer edges and at the same time we have been able to
drastically reduce the use of polystyrene extensions,“ says a satisfied Van Renterghem,
adding that savings are also considerable.
Because of the boom, which construction in prefabricated concrete sections has been
experiencing for several years now in the Benelux countries, Prefaco decided on a
modernisation of the carrousel system at the Wieze (Lebbeke) site in Eastern Flanders.
„Our master computer was old, the system was not automated, and the shutters had
to be placed manually. All this had consequences for the quality of the products - it was
time to invest, in order to cope with the high quality requirements,“ explains Prefaco‘s
Project Manager, Jean Pierre Van Renterghem.
Form Master improves product quality and rates of production.

COMPANY
Albert Regenold GmbH
LOCATION
Bühl-Vimbuch, Germany
START OF PRODUCTION
2016
TYPE OF PLANT
New carrousel plant, modernised
production of made to measure mesh
DOUBLE WALL PIONEER
FIT FOR THE FUTURE
A company with an eye to the future
Forward thinking has always been part of the corporate philosophy of Albert Regenold
GmbH from Bühl-Vimbuch in the centre of Baden. It is no accident that this traditional
precast concrete element producer was involved in the 1960‘s in the development of
the concept of the double wall.
and the spreading of fresh concrete by the automatic concrete spreader. In addition,
production of made to measure mesh has been modernised and the ebos ® control
system installed.
In order to secure a good starting position for the future, in 2016 Regenold decided to
invest in a new carrousel system with integral manufacture of made to measure mesh.
„The aim was to make the work easier for our staff, to shorten the routes and to reduce
energy consumption,“ explains the proprietor and Managing Director, Harald Sommer.
Double and solid walls as well as lattice girder floors are manufactured on a total of
50 pallets. 60% of production volume is devoted to ceilings and 40% to wall panels.
According to Regenold the high degree of automation has a very positive impact on
two stations in particular on the production process and product quality: the shuttering
and de-shuttering of the pallets by the Form Master shuttering and de-shuttering robot
From left to right: Uwe Sommer (Managing Director), Harald Sommer (Proprietor and Managing Director)
and Frank Frey (Technical Manager and Project Manager)
GERMANY MODERNISED
Max Bögl
Successful change of control system
In the second half of 2016 the Max Bögl Group,
one of the largest technology and service provider
firms in the German construction industry, decided
to restructure the precast concrete plant at its
headquarters in Sengenthal and to update the
control system to the latest standards. „We were
finding it almost impossible to obtain spare parts
and we cannot afford downtime during our 24-
hour operating schedule. Something had to be
done,“ explains the works’ Production Manager,
Christian Rackl. Among other retrofits the ebos ®
control system was implemented for the carrousel
control system and integrated into the existing ERP
system. It is once more „full steam ahead“ for the
production of solid, sandwich and façade elements
and railway sleepers.
fdu Consortium
Modernisation of six sites
The fdu Consortium, the largest provider of lattice
girder floors, double walls and other precast
concrete elements in Germany, commissioned
EBAWE Anlagentechnik with undertaking a
variety of modernisation measures at a total of
six productions sites. It took less than a year to
complete. Compacting equipment was refurbished,
new turning equipment and made to measure mesh
machinery were installed and pallets and shuttercleaning
devices were replaced. The Managing
Directors of both sites, Thomas Beike und Jörg
Vennemann describe the concerted modernisation
of no fewer than six plants as the „right step for the
future“. They express themselves satisfied with the
results: „We have boosted major production sites.
For years the PROGRESS GROUP has been the
partner of our choice for modernisation projects.“
Karl Bachl
Precast concrete element division boosted
The Karl Bachl Group is expanding its portfolio in
the prefabricated concrete section sector with the
extremely popular double wall and for this purpose
recently began operation of a new carrousel system
with a refurbished manufacturing system for made
to measure mesh. Norbert Peter, the Manager of the
Business Division expresses his conviction that the
expansion of the product portfolio to double walls
was the correct step to take: „There is no wall system
as suitable for our times - it is future-proof, costeffective
and also saves energy.“ He also believes
that this applies also to the Thermowand thermal
wall, a double wall with integral thermal insulation.
As well as automated solutions such as shuttering
robots and fully automatic concrete spreaders, a
fully automatic insulation material cutter has been
installed for cutting the insulation materials required.
Max Bögl Bauservice GmbH und Co. KG
Head office: Sengenthal, Germany
Employees: 6,000
fdu GmbH & Co. KG
Head office: Georgsmarienhütte, Germany
Employees: 952
Karl Bachl GmbH & Co. KG
Head office: Röhrnbach, Germany
Employees: 1,800

NEWS
MESH SPACER
Automatic positioning of spacers
A new robot system from Progress Maschinen & Automation makes an operation,
which hitherto has been carried out manually, superfluous: the Mesh Spacer special
solution places spacers specific to rebar mesh fully automatically on the production
pallet, controlled by CAD-CAM data. Optimum positioning is calculated by an in-house
algorithm and controlled by an integral laser system. This guarantees an even concrete
surface. Automating this operation means that on one hand the number of spacers
can be reduced to a minimum and at the same time the quality of the precast concrete
element can be improved.
Progress Maschinen & Automation AG | www.progress-m.com
3D SHUTTERING MOULDS
Prefabricated bathrooms for Singapore and Bangkok
Tecnocom, the specialist for special mould systems, supplied a total of seven 3D
shuttering moulds for the production of prefabricated bathrooms to Straits Construction
in Singapore and SCG Cement-Building Materials in Bangkok. The two companies use
these to manufacture completely equipped bathroom modules, which are installed in
the building on the construction site. Because of the adjustable wall shuttering and
base plate the moulds are characterized by a high degree of flexibility. Since these
bathrooms are 90% prefabricated, the costs and the production and installation times
are significantly reduced.
SLIPFORMER
Melbourne: Australian firm invests in slipformer production
The successful Australian producer of precast concrete elements, Westkon Precast
in Melbourne is investing in new technology from Echo Precast Engineering for the
manufacture of hollow core slabs. Production was started a short while ago. A Universal
Concrete Extruder with eight different tube and mould sets for the manufacture of hollow
core slab 1.20 m in width and 15 to 50 cm in height has been installed. In addition, prestressed
solid slabs for stadiums and mini slabs can be manufactured. Saws, an automatic
plotter, a multi-function trolley and suitable lifting equipment extend the plant.
Tecnocom S.p.A. | www.tecnocom.com
Echo Precast Engineering NV | www.echoprecast.com
SOFTWARE DEVELOPMENT
PSD expands development team
Progress Software Development (PSD), the seventh subsidiary company in the
PROGRESS GROUP, is building up a second team of developers in the Group‘s
office branch at Frankfurt Airport. PSD, which, with its three sector-specific software
solutions – the ebos ® und ProFit control systems and the e rp bos ® control system –
works successfully with reinforcement manufacturers and precast concrete plants
all over the world, is thus expanding its capacities to a significant extent. Customer
focus is also being significantly improved and at the same time this underlines the
PROGRESS GROUP‘s role as a turnkey supplier.
Progress Software Development GmbH | www.progress-psd.com
EBAWE Anlagentechnik GmbH | Dübener Landstraße 58 - 04838 Eilenburg - Germany | info@ebawe.de | www.ebawe.de