DESIGN, CONSTRUCTION AND INSTALLATION OF ... CONSTRUCTION AND INSTALLATION OF SPECIAL PLANT AND...

DESIGN, CONSTRUCTION AND INSTALLATION OF SPECIAL PLANT AND MACHINERY FOR INDUSTRY

COMPANY PROFILE

PLAN SRLVia delle Nebbie, 7 - 53043 Chiusi (Siena) ITALY

www.planitalia.it [email protected]

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Company ProfileCompany Profi le

company pro� le - Rev. 2 12/08

INTRODUCTION

“PLAN SRL” was founded in 1991 by Mr. Eugenio Lucheroni who currently serves as Chairman.

Over the past years “PLAN SRL” has become an industry leader in the design and manufacture of specialist production systems for the construction materials industry. This success is due in large part to the innovative solutions created by dedicated technical and production staff to satisfy customer needs.

The company has now supplied equipment to over 80 customers in 20 different countries.

Strict attention to European Codes means that all equipment is CE kite marked and is compatible with work-place safety regulations world-wide.

The company has over 90 permanent staff and designs, manufactures and in-stalls all components of each production system, trains client personnel and provides after-sales service, thereby ensuring maximum output and quality for each system.

The current range of products covers a wide spectrum, from sophisticated to highly automated plants for the production of high-tech concrete products such as railway sleepers, extruded hollow-core slabs and long span pre-stressed roof elements to individual machines for production and automation of indus-trial processes.

The company is member of:

FiB (Federation International du Béton);IPHA (International Pre-stressed Hollow-core Association);

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FIB (Fédération Internationale du Béton)

inserire foto membri IPHA pag.3 company pro� le

Commission 6 Prefabrication

Task Group 6.5 - Precast concrete railway track systems

Convener: Darroch (RMC Concrete Products, UK)Members: Albajar (Avisa, Spain), Beluzsar (Pfl eiderer, Hungary), Bilek (ZPSV, Czech

Rep.), Giannakos (Hellenic Railways Organisation, Greece), Kiefer (Creabeton AG, Switzerland), Lucheroni (PLAN SRL, Italy), Malmqvist (Abetong Teknik, Swe-den), Petit (Sateba, France), Salo (Consolis, Finland)

Corr. Members: Campbell (Australia), McQueen (P.J. McQueen Corp., USA)Meetings: Athens (May 03), Basel (Dec. 03), Avignon (Apr. 04), Paris (Oct. 04), Madrid

(Feb. 05), Prague (Jun. 05)

The FIP Commission on Prefabrication published in 1986 the “State of the Art” report on concrete railway sleepers. Since that time many changes and developments have taken place in the railway industry. The industry has adopted increased axle loads and speeds, and now widely uses precast concrete crossing bearers for switch and crossings. The use of slab track incorporating precast concrete is now used in special cases. The precast concrete industry has responded with new designs, more effi cient production methods and the adoption of highly effective quality assurance schemes. New codes of practice covering all aspects of precast concrete railway track prod-ucts from design and manufacture to installation and maintenance have been de-veloped. Methods and procedures have been universally adopted to ensure that the isolated occurrences of ASR and Delayed Ettringite that fi rst came to light in the 1980’s are avoided. There have been trials for railway track products using materials other than concrete.It is considered therefore that an updated state of the art report for precast concrete track products was timely and would demonstrate to the specifIer and end user that precast concrete track systems provide a durable, long lasting and economical solu-tion.

IPHA (International Pre-stressed Hollow-core Association)

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PLAN SRL LOCATION

Currently employs over 90 people in two factories:Factory 1

Factory 2

WHEREYOU CAN FIND US

All MACHINERY sold by PLAN is designed, manufactured and tested prior to ship-• ment in these two factories.

PLAN has shipped over 3000 machines from these factories. •

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PRODUCTS

CONCRETE RAILWAY SLEEPER FACTORIES

PRECAST AND PRESTRESSED CONCRETE ELEMENT FACTORIES

PRESTRESSED HOLLOW-CORE SLAB FACTORIES

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CONCRETE RAILWAY SLEEPERS

PLAN SRL

is the largest pure sleeper factory supplier in the world today and has the widest pos-sible experience in supplying working sleeper factories that fulfi ll client needs.

PLAN has a unique set of skills, not very common in sleeper factory manufacturers:

PLAN makes equipment and factories for concrete railway sleeper manufacturing �as its main business. PLAN has built 15 complete and 5 under construction factories in the last 5 years.

Wide experience in the production of concrete in diffi cult environments.�

In-depth knowledge of pre-stressing, not only as it relates to sleepers. �

Years of “hands-on” experience in sleeper production.�

“One stop shop”. PLAN can provide detailed, in depth advice and service on all �phases of sleeper manufacture:

- Aggregate Handling;- Batch Plant Specifi cations;- Mixers;- Concrete Plant Control System;- Concrete temperature Control;- Sleeper design;- Sleeper curing;- Sleeper storage;

32 successful projects in 15 years� ranging from 20 sleepers per hour to 140 sleepers per hour.

More than 40 straight “1st time” sleeper homologations. �

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CAROUSEL SYSTEM

Plan “carousel” method manu-facturing process is based on a non-stop horizontal or vertical carrousel conveyor featuring a continuous closed cycle. Moulds are moved simultaneously through the plant from one work station to the next in the produc-tion zone with cured sleepers moving along the fi nishing line. At each work station the differ-ent phases are executed, with computerised quality control keeping records of each critical operation. The production phases can be fully or semi-automated depending on customer pref-erence. Using Plan “carousel” method plant it is simple to produce different kinds of sleepers (different dimensions, different tensioning load and rail fastening...) during the same working shift.

MARGAPLAN® SYSTEM

As a result of this experience and in anticipation of strict new EC regulations for pre-stressed concrete in 2000 Plan fi nished development of the new MARGAPLAN® system for post-tensioned, high performance sleepers directed toward inclusion as part of the permanent way of the latest generation of high speed lines being planned around the world. Sleeper manufactured using the MARGAPLAN® post-tensioned system is used throughout the Italian Railway System (RFI) with excellent results, for example the high speed line Milan – Turin and the high speed line Florence – Bologna with the new speed record of 350.8 km/h without vibration.

PLAN was the fi rst plant manufacturer

to have successfully homologated sleepers in complete compliance the newest

European Norms 13230

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PLAN is the only plant manufacturer which has successfully homologated different sleepers using different technologies with the carousel system

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RAILWAY TURNOUT SLEEPERS

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AUTO DATA COLLECTION AND STORAGE

Data of each machine are collected and stored in a Windows® PC with the chance to control the production at distance. Each mould is equipped with a bar-code iden-tifi cation tag.

CONCRETE CURING AUTO DATA COLLECTION AND STORAGE

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BALLASTLESS TRACK

PLAN SRL

also supplies moulds and production

linesfor ballastless track

(also know as “slab track”)applications ranging

from Light Rail Transit to regular rail system

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PLAN SRL

offers various solutions for turnkey factories dependingon the structural systems and production capacities required

by the Client and the availability of local resources.

PLAN makes equipment and factories as its main business;�

Wide experience in the production of concrete in diffi cult environments;�

In-depth knowledge of element design, pre-stressing, handling (in the fac-�tory and at the site), and installation;

Years of “hands-on” experience in precast production and installation;�

“One stop shop”. PLAN can provide detailed, in depth advice and service �on all phases of pre-cast concrete manufacturing:- Aggregate handling;- Batch plant specifi cations and mixers;- Concrete temperature control;- Precast product design;- Precast product curing;- Precast product storage;- Precast product transport;- Precast product installation/erection;

PLAN supplies:

Automated factories for the production of Industrial / Commercial struc-�tures (foundations, columns, beams);

Automated factories and machinery for the production of hollow-core �slabs;

Automated factories and machinery for the production of roof elements;�

Automated factories and machinery for the production of wall panels;�

CONCRETE PRE-CAST ELEMENTS

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PRODUCTION CENTRE FOR COLUMNS

The PLAN solution for the production of concrete columns provides a fast and fl exible system for the production of pre-cast columns with varying sizes, using a minimum of labour and ensuring that the producer can modify the production centre and cast different columns every single working shift.

PLAN production centre allows to produce columns from 500x500 to 800x1000 mm including all the intermediate sections by the use of interchangeable modular bot-tom shutters that are positioned with a simple interlocking system and are adjusted to height, in pre-set positions, by hydraulic actuators. It also allows the producer to place corbels on any side and at any spacing that may be required. This is accomplished by modular infi ll elements which have the shape of the desired corbel and replace the modular shutter elements in the position required. The side shutters are opened and closed by hydraulic cylinders and the bottom shutter moves sideways when the side shutters open, making stripping a stress free operation, both for the pre-cast unit and the operator.

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PRODUCTION CENTRES FOR PRESTRESSED BEAMS

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ROOF INFILL PANEL PRODUCTION

a) Automatic stripping b) Automatic handling

c) Insulation application d) Water proofi ng

e) Steel cladding f) Soffi t painting

g) Automatic packing

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HANDLING SYSTEMS

40 Ton machine for wall panel transport/washing

12 Ton machine for reinforcement cage transport

200 Ton machine for hollow-core slab transport

200 Ton machine for long-span roof element transport

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STRONG BACK BEAMS

12 Ton self-levelling strong back beam for column and beam handling

12 Ton self-levelling strong back beam for wall panel handling

15 Ton self-levelling for special hollow-core slab handling

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PRE-STRESSED HOLLOW-CORE

PLAN SRL

Offers the most cost effective hollow-core production system

in the market.

The PLAN hydraulic extruder is the lowest “life-cycle cost” machine

available (including slip formers)and the initial investment cost is very competitive.

Stressing, stripping, cleaning and handling systems are all highly automated,

easy to use andreasonably priced.

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BED PREPARATION

TECHNICAL SPECSDimensions (meter)• 3.5 x 2.0 x 2.35 (h)Weight• 32 kNExtrusion speed• 0-40 m/minConnection power• Industrial battery 80 VElectrical absorption• (battery charger 5 kW)

Bed cleaning with a rotating brush to remove dust and debris from the •casting bed’s surface (including the rails);

Pulling strands along the casting bed (up to no. 10 strands at the same •time);

Oil distribution (protecting the strands), applying release agent (form •oil) to the casting bed surface;

Bed cover placing and removal•

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TECHNICAL SPECS ST-50 SAWSpeed of cut for longest blade life 650 mm/min for H400 slab section

(2 minute cycle time)900 mm/min for H200 slab section

ST-40 saw capable to cut up to 1200x420mm



CUTTING

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SOUND BARRIER PRODUCTION

Cutting machine

Casting machine

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Customername

Country Year Main characteristics

Production system Type of railwaysleepers

IANNARILLI ITALY 1994 Fixed plant 25 sleepers/hour

Pre-tensioned system (button headed wires

with end anchor plates)

FSV 35

CEVIP ITALY 1996 Fixed plant 75 sleepers/hour



FSV 35

VIANINI ITALY 19961997

Fixed plant 140 sleepers/hour



High Speed sleepers

VIBROBETON CROATIA 19971998




B70

ICEP ITALY 19971998




FSV35

LODOVICHI ITALY 19971998

Fixed plant (re-novation & up-grading) 90-130 sleepers/hour



FSV35

PIZZAROTTI ITALY 1998 20032005

Fixed plant (re-novation & up-grading) 70-120 sleepers/hour



FSV35 – High Speed

SINTA TURKEY 1999 Fixed plant 25 sleepers/hour



B58

ZAODON-TRADE

UKRAINE 1999 Fixed plant Pre-tensioned system Plant design

EDILE FERROVIRIA

ITALY 1999 Fixed plant 90 sleepers/hour



FSV 35

MARGARITELLIITALIA

ITALY(Chivasso)

2000 Mobile plant14 turnouts/hour

“MARGAPLAN”Post-tensioned

system

Turnoutsleepers2100 to

4800/6600m length

REFERENCES (Concrete sleepers)

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MARGARITELLI ITALIA

ITALY (Casoli)

2001 Mobile plant75 sleepers/hour

“MARGAPLAN”Post-tensioned system

RFI 230, 240, 260 (High Speed) – Tram sleepers (Pan-drol - Vossloh)

MARGARITELLI I TALIA

QC according to EN 13230

ITALY(Rodallo)

2003 Fixed plant(1st production line)90 sleepers/hour


RFI 240 –RFI 260 (High Speed)(Pandrol - Vos-sloh)

MARGARITELLI ITALIA


ITALY(Rodallo)

2003 Fixed plant(2nd production line)60 turnouts/hour


Turnoutsleepers2100 to 4800/6600 m length

MARGARITELLIITALIA


ITALY(Rodallo)

2004 Fixed plant(3rd production line)90 sleepers/hour


RFI 240 –RFI 260 (High Speed)(Pandrol - Vos-sloh

TRAVERSUD(PIZZAROTTILODOVICHI)QC according to EN 13230

ITALY 2005 Fixed plant140 sleepers/hour

Pre-tensioned system (button headed wires with end anchor pla-tes)

RFI 260 (High Speed)(Pandrol - Vos-sloh

LODOVICHIQC according to EN 13230

ITALY 2005 Fixed plant Pre-tensioned system (button headed wires with end anchor pla-tes)

Turnoutsleepers 6.60m length

MARGARITELLIITALIA

ITALY 2005 2 Slab tracks/hour Reinforced Slab track for LRT

THEMOSGREECE 2005 Mobile plant

40 sleepers/hourPre-tensioned system(improved adhesion wires)

TBS1000 Metric gauge slee-pers (Vossloh)B70 (Vossloh

I CEPQC according to EN 13230

ITALY 2006 Fixed plant100 sleepers/hour

Pre-tensioned system (button headed wires with end anchor plates

RFI 230, 240, 260 (High Spe-ed)(Pandrol - Vos-sloh

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LEONHARDMOLL

(Factory IN-FRAFER in Ain

Sefra)

GERMANY(ALGERIA)

2007 Mobile plant 65 sleepers/

hour

Reinforced Twin-block sleepers (future

production of B70 pre-stressed mo-nobloc sleepers)

ITALSLEEPERSQC according

to EN 13230

ITALY 2007 Fixed plant 100 sleepers/hour

“MARGAPLAN”Post-tensioned

system

RFI230, RFI240, RFI260 (high spe-

ed)(Vossloh)

HIS INDUSTRIES PAKISTAN 2007 Mobile plant 50 sleepers/

hour

Pre-tensionedsystem (impro-ved adhesion

wires)

Sleepers length 2750mm

(gauge 1676mm) (Vossloh)

YAPI MERKEZI (ROCLA

CONCRETE TIE)

Turkey U.S.A.) 2008 Mobile plant 50 sleepers/

hour

Pre-tensionedsystem (but-

ton-head wires with end an-chor plates)

B70 (Vossloh)

VOSSLOHFASTENING

SYSTEMS (CXT, LB FOSTER)

GERMANY(U.S.A.)

(workin progress)

Moulds 6 cell gang moulds for

long-line plant

105S-V1 tie(Vossloh)

PRECON SPAIN (Venta de Baños)

2007 Fixed plant (renovation

& upgrading) 40-90 sleepers/

hour

PRECONPLANPost-tensioned

system

FEVE (1900), PR, Al, MR (2600), AM

(2750)

SILVERY DRA-GON

CHINA 2007 Plant for the manufactureof reinforce-

ment

Pre-tensionedsystem

(improvedadhesion

wires)

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MARGARITELLIITALIA


FRANCE (work in progress)

Moulds “MARGAPLAN” Post-tensioned

system

M260 PI M450 PI (Fast Clip)

YAPIRAY Turkey (work In progress)

Mobile plant 50 sleepers/

hour



B70 (Vossloh)

S.A.M SAUDI ARABIA (work in progress)

Mobile plant 80 sleepers/

hour



Sleepers 2600 mm, 32 Ton axle load (Vossloh)

XKD CHINA (work in progress)

Fixed plant100

sleepers/hour

Reinforced Twin-block sleepers

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Customername

Country Customer name

Country Customer name

Country

AMADONHUNGARY Hungary

HOLLOWCORE SYSTEMS

UK (Factory: Saif Noman Said, KSA)

R.D.B.CENTRO

Italy

AREAPREFABBRICATI

Italy IAPITER Italy REKON-IZHORA Russia

ARGA NAVES INDUSTRIALES

Spain IMPRESA PIZZAROTTI

Italy RESTUCCIA CO-STRUZIONI

Italy

BARRIKADA Russia INPES PREFABBRICATI

Italy SAM. ENGINEERING

Italy

BENTINI COSTRUZIONI

Algeria IPA PRECAST Italy SARBI Russia

CALDANA Italy ITALPREFABBRI-CATI

Italy SERIOPREFABBRICATI

Italy

CENTRO ITALIA PREFABBRICATI

Italy L.C.A. FUTURE SYSTEMS

Italy SHEBH AL JAZERA

Saudi Arabia

CO.PAR.FIN Italy MC-MANINI PREFABBRICATI

Italy S.I.C.E.P. Italy

COOPERATIVADI

COSTRUZIONI

Italy MC PREFABBRICATI

Italy ST.I.ARM Italy

C.S.P.PREFABBRICATI

Italy MABO PREFABBRICATI

Italy STRONG & MIBET EPITOELEMGYAR

Hungary

DELTA SUD Italy MAGNETTI BUILDING

Italy TAV Romania

EDILCEMENTO Italy MAGNETTI PREFABBRICATE

Romania TAV SOLAI Italy

EDILGORIPRECOMPRESSI

Italy MANINI PREFABBRICATI

Italy TECNYCONTA Spain

ESCOSA Costa Rica MANINI PREFABBRICATI

LAZIO

Italy TRAVISUD Italy

F.C.M. Italy OFFICINE PICCINI

Italy TROST Germany

F.I.M. Italy PAMA PREFABBRICATI

Italy VALLEMME PRE-FABBRICATI

Italy

FORNACISCANU

Italy PREFABBRICATI PUGLIESI

Italy VIBROBETON Croatia

FRATELLIBIGNAMI

Italy PRE-FORM Italy VIBROCEMENTO

Italy

GALAZZOPREFABBRICATI

Italy PRELESA Spain VIBROSUD Italy

REFERENCES (Pre-Cast elements)

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GENERALEPREFABBRICATI Italy

PRETENSADOSIDUSTRIALES(SINERCON)

Dominicanrepublic

VIPRECOSTRUCOES

Brazil

GHEDEMPRE-CAST

Eritrea PROFER SYSTEM Italy WEILER ITALIA Italy

G.R. IINDUSTRIES

Belgium PREP Italy

HORMY MECO Spain QUATAR PRECAST

Quatar

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