Embed Size (px)
Citation preview
CPI – Concrete Plant International – 2 | 2011 www.cpi-worldwide.com192
PRECAST CONCRETE ELEMENTS
Planning/building phase
In order to be able to fulfil these specialrequirements – up to that point only unten-sioned concrete elements could be manu-factured – initial consideration was given in2008 to a universally usable formwork forprestressed concrete parts. Intensive discus-sions were held and the most diverse va -riants were considered. As a long-standingsupplier, Avermann was involved in theplanning of the plant from the outset. Abasic concept was developed at an earlystage that immediately fulfilled the expecta-tions of the sole owner of HV BetonwerkAnhalt, Mr. Vedder, and only needed to bespecified more precisely in the details. Theuniversal orientation of the formwork con-cept in particular, but also the high require-ments with regard to precision and produc-tion quality led at the end of 2009 to theplacing of an order for the formwork withAvermann Maschinenfabrik GmbH, Osna -brück. The associated prestressing equip-
ment was purchased from Paul Maschinen -fabrik. The existing seven buildings werealready working at full capacity, whichmeant that a new production facility had tobe built on a “green field site” opposite theexisting works site. The construction workfor the approx. 240 x 45 m hall (2 aisles),including the adjacent warehouse area of afurther 160 x 45 m, took until the late summerof 2010 to complete. The production equip-ment was subsequently installed.
Hydraulic universal formwork
As mentioned above, the Avermann form-work was designed for the widest variety ofapplications. The formwork is located in acorresponding prestressing bed, which isequipped with the necessary prestressingequipment.
Hence, several concrete parts having thesame geometry and prestressing can bemanufactured inside the 99 m long form-
work. The formwork is primarily conceivedfor the manufacture of prestressed concreteparts. Untensioned concrete parts (e.g.columns) can also be produced if necessary;however, this will most probably be anexceptional case, since in this regard furtherformworks without prestressing beds areavailable at HV Betonwerk Anhalt.
The basis for the universal formwork is a 99 mlong base frame formwork with hydraulicallymovable lateral grids on both sides. Thismovement is accomplished by double-action hydraulic cylinders in conjunctionwith a mechanical synchronising shaft.Depending upon requirements, this cantake place over the entire length, or dividedinto 2 or 3 sections.
The load is maintained below by means ofmechanical prestressing blocks; additionalover-tensioning is necessary above, depend-ing on the dimensions and geometry of theconcrete parts.
99 m long hydraulic universal formwork for
the production of prestressed concrete parts
in operation at HV Betonwerk Anhalt
Avermann Maschinenfabrik GmbH & Co. KG, 49078 Osnabrück, Germany
HV Betonwerk Anhalt was founded in 1992 in Löbnitz/Köthen, Saxony-Anhalt, Germany, and employs around 200 people. Precast parts are
produced for the domestic and foreign markets in a total of 9 production buildings using state of the art technology. The central location as
well as the procurement of raw materials from the immediately surrounding area enables the precast concrete works to supply a large
catchment area economically. Production is mainly focused on filigree wideslabs and double walls as well as solid elements and sandwich
façade elements. These products are manufactured on pallet circulation plants made by Avermann Machinenfabrik. Beyond that, various spe-
cial parts such as columns, girders, beams, stairs, balconies etc. are manufactured in Löbnitz/Köthen. However, the manufacture of complex
concrete structures with bar-shaped prestressed concrete parts for office buildings and industrial halls is increasing in importance.
Various production cross-sections using the universal formwork Overall view of the 99 m long universal formwork
www.cpi-worldwide.com CPI – Concrete Plant International – 2 | 2011
PRECAST CONCRETE ELEMENTS
Operating station with hydraulic and vibrator control
Manufacture of the reinforcement cage
Ostensibly designed for the manufacture of single and doublebeams up to a maximum height of 2,400 mm, parallel beams orgable roof beams can alternatively be manufactured. The bottomand top chord geometries are implemented in steel; the ribs areadjusted to the respective size by means of Betoplan boards. Thisalso enables the infinite setting of any angle of inclination for thegable roof beams.Depending on the necessary geometry of the concrete part, otherhook-in parts can also be positioned on the base frame formwork.Thus the most diverse cross-sections can be manufactured for theproduction of girders, beams, bridge beams and the like. The form-work can also be modified by the retrofitting of a central steel gridwall and used as a twin formwork.
The concrete elements are compacted by means of high frequencyvibration. A total of 96 Avermann vibrators are fastened to thevibrating guide profiles of the side walls; they are controlled in sixsections, each with 16 vibrators. The vibrators are driven by an 18.5kW frequency converter controller, infinitely adjustable between 20and 200 Hz. The commands are given by a radio remote control inconjunction with large-sized displays for displaying the set frequencyand vibration group.
For all of your customers’ needs...
Why are smart precast professionals choosing
concrete insulation systems from Thermomass?
Thermomass systems are environmentally
responsible and have been used in a variety
of green-built and LEED-certi� ed projects.
Thermomass products boast decades of
third-party testing, an industry-trusted
evaluation report (ICC-ES), and various
product approvals (DIBt and more).
Our representatives have expert, hands-on
experience providing schematic design
assistance and engineering support for
insulated precast walls.
No matter which customer you are serving -
code o� cial, architect, engineer, or developer -
we have a Thermomass solution for their needs.
For more information, call +49-6251-790890 or
visit us online at www.thermomass.de.
THERMOMASS® is the solution!
Developer Architect Engineer Code o� cial
Green, LEEDTM
certi� cation
Design
� exibility
Trusted
calculations
Documented,
tested materials
CPI – Concrete Plant International – 2 | 2011 www.cpi-worldwide.com194
PRECAST CONCRETE ELEMENTS
Several 40-tonne double-girder bridge cra-nes are installed in order to enable the set-ting up of the formwork as well as the sub-sequent lifting out of the finished parts.
Prestressing equipment
The plant is designed for a prestressingforce of 8,000 KN in the main reinforce-ment and 1,000 KN in the transport rein-forcement and has a prestressing torque(force over prestressing line) of 8,000 kNm.
For the absorption of the prestressing forceand the prestressing torques, an abutment
type P VI from the Paul company was built,which can absorb a prestressing torque of3,100 KNm and a prestressing force of4,000 KN per metre width of the counterbearing. The building material requirementsfor this abutment amount to approx. 30cbm of concrete and approx. 2.5 tonnes ofstructural steel per metre width of the abut-ment. The prestressing line thickness is 40cm. It runs without joints between the twoabutments.The production sequence is as describedbelow. The reinforcement cages are wovenalongside the formwork, equipped with ten-sioning strands and subsequently lifted into
the formwork and aligned. The tensioningstrands are coupled with single-wire coup-lings and tensioned after the closure of theformwork.
The single-wire prestressing jack is equippedwith the TENSAcontrol measuring system,which logs the prestressing process andsaves a tensioning force-elongation log foreach tensioning strand. Once the structuralelements have set, the tensioning force istransferred to the structural elements byrelaxing the appropriate hydraulic cylinders.
The prestressing steel reinforcement is shovedinto the reinforcement cage by means of anelectric pushing device.
Conclusions and outlook
After many years of low investment at HVBetonwerk Anhalt, a remarkable new pro-ject was implemented last year.The investment into prestressed concretetechnology at HV Betonwerk Anhalt meetsthe growing demands for complex concretestructures for the manufacture of commercialbuildings in particular. The ability to supplybar-shaped prestressed concrete parts hassignificantly expanded the company’s mar-ket position.
All construction and installation work wascompleted in November 2010 and wasimmediately followed by the production ofthe first beams.
Due to the extreme formwork length of 99 m,4-5 identical elements can usually be manu-factured in parallel in the universal form-work, depending on the dimensions of theconcrete parts. This allows even large quan-tities to be supplied within the shortest time.
Prestressing technology by the Paul company (relaxation side)
Formwork with hook-in parts for beams
Lifting out a gable roof beam
In addition, the short setup times and low warehousing costs allowthe company to keep one step ahead of the competition.Preparations have already been made in the new production build -ings for a possible extension of the manufacture of prestressed con-crete elements. Thus additional pits for a further 100 m prestressingbed were already provided for in the planning of the buildings. It isalso planned to optimise the filling of the universal formwork in thenear future by the use of a special concrete distributor.
Mr. Vedder and the entire management of the precast works weredelighted with the quality and functionality of the delivered equip-ment from the outset. The first large orders have already been com-pleted and the formwork will be working at full capacity in thecoming months.
M
www.cpi-worldwide.com CPI – Concrete Plant International – 2 | 2011
PRECAST CONCRETE ELEMENTS
FURTHER INFORMATION
Avermann Maschinenfabrik GmbH & Co. KGLengericher Landstraße 3549078 Osnabrück, Germany T +49 5405 5050F +49 5405 [email protected] www.avermann.de
HV Betonwerk AnhaltRingstraße 106369 Löbnitz/Köthen, Germany T +49 3496 50200F +49 3496 550149 [email protected]
PAUL Maschinenfabrik GmbH & Co. KGMax-Paul-Straße 188525 Dürmentingen, Germany T +49 7371 5000F +49 7371 [email protected]
Max-Paul-Straße 188525 Dürmentingen / GermanyPhone: +49 (0) 73 71 / 5 00 - 0Fax: +49 (0) 73 71 / 5 00 - 111Mail: [email protected]
Maschinenfabrik GmbH & Co. KG
The experts in Prestressed Concrete Technology.
PAUL supplies
Prestressing installations incl. •
planning workAnchor grips• Prestressing machinery• (single-/multi-stressing jacks)Strand pushing and cutting equipment• Automatic prestressing machines for • railway sleepersPrestressing equipment for bridge • construction(prestressing cables and stay cables)
Pure flexibility.
Production of hollow core slabs
