Kaspar Röckelein KG, 96179 Rattelsdorf, Germany Röckelein relocates its lattice ......

CPI – Concrete Plant International – 4 | 2013 www.cpi-worldwide.com152

PRECAST CONCRETE ELEMENTS

Mark Küppers, CPI worldwide, Germany

For some 66 years now, the family-ownedcompany founded in 1946 by KasparRöckelein has been developing and pro-ducing high-quality building materials fromconcrete as well as brick-built houses,which are marketed under the nameRÖWA-Massivhaus. Through a mixture ofexperience, innovative spirit, tradition andprogress as well as economic far-sighted-ness and a willingness to take risks, theRöckelein company has succeeded inattaining a high rating for its products andconsiderable market strength. TodayRöckelein manufactures its products at foursites: Wachenroth (head office), Rattelsdorfand Altendorf in the Bamberg region(Bavaria) and Osterfeld (Saxony-Anhalt).

The constant development of the companyhas been successful up to the present dayand has reached a new, shining peak withthe putting into operation of the new latticegirder slab production plant in the Ebingworks at the Rattelsdorf site.

Only three suppliers realised a tailor-made solution

In the implementation of the large-scaleproject at the Ebing works, Röckeleinattached a great deal of importance to acomplete solution from one source. Apartfrom the companies already named, whosupplied the equipment for the concrete

Kaspar Röckelein KG, 96179 Rattelsdorf, Germany

By relocating its lattice girder slab production from the Wachenroth site to the Rattelsdorf site some 45 km away, Röckelein is able to makethe work processes for this product segment considerably more economical. The Rattelsdorf site, where products for underground con-struction, concrete blocks, chimneys and ready-mix concrete have mainly been produced until now, also has its own gravel pit, from whichall of the aggregates for its own production are obtained. Whereas the raw materials previously had to be driven by truck into the Wachenrothworks, the aggregate silos are now filled directly from the gravel pit with its sorting and crushing units.In order to realise the state-of-the-art lattice girder slab plant at the Rattelsdorf site, Röckelein erected a new twin-aisle production buildingwith a total floor area of 7,200 m². After a short dry-run phase the first lattice girder slab was produced on 17 August 2012 and already metthe company’s high quality requirements.The lattice girder slabs are manufactured on a pallet circulation plant from Ebawe Anlagentechnik GmbH with extensive automation tech-nology. Major parts of the circulation plant are the modern systems for reinforcement processing and placement from Progress Maschinen& Automation AG, an affiliated company of Ebawe. In addition to processing stations for the longitudinal and transverse reinforcement, thismodern circulation plant is characterised by the integration of a lattice girder welding machine, which is new on the market from Progress.For the supply of high-quality concrete the Liebherr company erected an impressing mixing tower, which stands directly adjacent to the newbuilding.

Röckelein relocates its lattice girder slab productionand sets clear pointers for the future with investmentinto high-performance production technology

Röckelein produces lattice girder slabs with the new circulation plant from Ebawe andProgress at the Ebing site in Rattelsdorf. So far production emphasis has been placed onproducts for underground construction, in particular concrete pipes.

On the works site at the Ebing location there is also a gravel pit that supplies exclusively thecompany’s own production with raw materials.

El

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The new Liebherr Betomat IV-685 mixing tower

production and the complete pallet circula-tion including the reinforcement machines,the Kübat company was commissioned tointegrate a concrete bucket track. Co-oper-ation and consultation between the suppli-ers proceeded to the entire satisfaction ofmanaging director Wolfgang Röckelein.

Great attention is paid at Röckelein to theutilisation of all aggregates obtained. Thepreparation of the aggregates in the gravelpit is fully automatic, as is the further trans-port to the storage silos for the mixingplants. This gives Röckelein great competi-tive advantages which, in combination withmodern and efficient machinery, have setup the company very well for the future.

New mixing tower for Rattelsdorf

The Liebherr company installed a mixingtower of the type Betomat IV-685 for thesupply of concrete to the new lattice girderslab production plant. The aggregates fromthe company’s own gravel pit are trans-ported by an inclined conveyor to a heightof around 40 m and poured into one of theten silo chambers via a rotating distributor.

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A RIM 2.25 ring pan mixer with mechani-cal agitator and two outlets was installedfor the lattice girder slab production, whichwent into operation in August. The concretecan be transferred via the two outlets either

into the Kübat bucket conveyor for transportto the lattice girder slab production ordirectly into a truck mixer, which can bepositioned under the mixer and fed directlyfrom above.

The new mixer is equipped with its ownfeed silo and separate cement and waterweighers. Modern technology and theproven Litronic MPS III mixing plant con-troller from Liebherr ensure the smooth pro-duction of high-quality concretes. In orderto ensure smooth operation at low temper-atures also, the entire plant was clad withsheet-metal-jacketed insulating elementsand equipped with a heating system fromSauter.

An addition, an exhaust air filter system anda residual concrete recycling unit were inte-grated into the Betomat IV-685 mixing tower.

Everything from once source – modernpallet circulation plant with reinforce-ment automation for high hourly output

The complete plant equipment for the latticegirder slab production in the new buildingwas supplied by the affiliated companiesEbawe Anlagentechnik GmbH andProgress Maschinen & Automation AG. Thecore competencies lie in the development

The raw materials are conveyed directly from the gravel pit into thestorage silos of the mixing tower by the 120-metre-long conveyorbelt.

The aggregates are placed into the appropriate silo by the rotatingdistributor. For the larger diameters, built-in steps ensure gentle fill-ing of the material.

View of the formwork removal area and the drying chamber behindit. Parallel to the formwork removal station is the concreting station,from where the formwork pallets are driven into the drying store.

Formwork robot in a special version for the simultaneous transport of 2 formworks, with plotter and cleaning/release agent sprayingstation. Here the formworks are removed by the robot, cleaned via a conveying track and transported to the formwork store.

The VGA Versa lattice girder welding machine operates from the coil and produces bothstandard lattice girders with different heights and custom lattice girders with strengthenedchords and diagonals just in time.

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and erection of complete precast concreteplants, which are equipped with modernpallet circulation plants from Ebawe as wellas machines from Progress for the process-ing of reinforcing steel.

Röckelein has had a good partnership withProgress Maschinen & Automation AG formany years. Hence, managing directorWolfgang Röckelein was able to fall backon positive experiences with previously pur-chased machines when it came to decidingin favour of a plant package from Ebaweand Progress.

The installed plant impresses through itshigh degree of automation and enormousoutput, which is defined by pallet size andcycle times. The automatic work processesof the circulating plant are controlled by acentral control system. All work stations arethus fully networked with one another andall processes can be followed and opti-mised centrally.

Formwork robot for precise placement of the formworkThe Form Master formwork robot takes careof both the removal of the formwork fromthe formwork pallet after removal of thehardened concrete elements and the place-

ment of the formwork for the new produc-tion cycle. When removing the formwork,the robot detects the formwork on the palletusing a new scanning method and removesit fully automatically.

When placing the formwork, the robotreceives its information directly from theCAD data, selects the necessary profilesfrom a magazine and places them precise-ly on the formwork pallet. Exclusively form-work from Ratec is used.Special, non-standardised formwork partsare placed manually on the formwork sur-face in the subsequent workstation. Theposition of the formwork is plotted automat-ically on the formwork pallets by the robot.

Pallet cleaning and release agent spraying unitThe lattice girder slab production atRöckelein, which is designed for high output,operates with formwork pallets measuring17.5 x 2.4 metres. In each new circuit theempty pallets first pass through the pallet

Lattice girders can be welded individuallywith the VGA Versa. With this high-techplant both the top and bottom chords andthe diagonal wire can be changed.

The lattice girders manufactured are either intermediately stored inthe magazine or fed directly to production.

The multi-axis robot places the lattice girders and longitudinal rein-forcement from the central magazines in position. While the straight-ening machine is producing the longitudinal bars and placing themon a chain magazine, the lattice girder magazine below it is con-veying the freshly produced lattice girders toward the pallet.

Progress came up with a special solution for the reinforcement: thestation contains two straightening machines for the production oflongitudinal and transverse bars, the corresponding automatic spac-er supply and two robots for the precise placement of bars and lat-tice girders.

The respectively necessary spacers are supplied from the three sort-ing pots to the reinforcement machine, which subsequently pullsthem onto the transverse reinforcing bars.


MBK Maschinenbau GmbHFriedrich-List-Str. 19 | 88353 Kisslegg / GERMANYTel +49 (0)7563 9131-0 | Fax +49 (0)7563 2566www.mbk-kisslegg.de | [email protected]

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since 1961

Characteristics:

• Customized solution through modular plant system.• Compact plant design requires little space

(35 x 12 x 4 mtr. / L x W x H).• Performance capacity up to 400 m² per hour.

Higher productivity on demand.• CAD based mesh welding with windows and door openings.• Reinforcement meshes for floors and walls welded on the same

machine equipment.• No subsequent rotation required.• Rigid construction of the pallet circulation.

Low maintenance required.• Subsequent system expansion possible.• Extendable with bending equipment.• Nr. of wire diameters from 3 to 6.• Wire diameters standard from 6 - 12 and optional to 16 mm.• Center to center 50, optional 25 mm.• Shortest bar 400, optional 200 mm.• Shortest spacing 100, optional 50mm.• Base execution with 2 welding heads, extendable to 4.

MSM-MMesh welding machine - Modular

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cleaning and release agent spraying unit.Following coarse cleaning by scrapers andfine cleaning by means of laterally rotatinground brushes for the lateral formwork androtary roller brushes for the formwork sur-face, the release agent is applied to theformwork surface of the formwork pallet.The release agent can be applied either tothe entire formwork surface or just to the sur-face to be covered with concrete.After being cleaned, sprayed with releaseagent and fitted with formwork, the form-work pallets are then moved following theplotting of the slab outlines to the manualformwork station for additional work andthen in the following cycle step to the pro-cessing station for the insertion of the rein-forcement.

‘Just in time’ lattice girder productionIn addition to fully automatic machines forthe manufacture of longitudinal and trans-verse reinforcements as well as their instal-lation by robot, Progress Maschinen &Automation AG also supplied a lattice gird-er processing centre, in which the VGAVersa lattice girder welding machine withautomatic height adjustment produces indi-vidual lattice girders fully automatically. TheVGA Versa lattice girder welding machineis a new product from Progress Maschinen& Automation AG and was presented to thetrade audience for the first time at the wire2012 in Düsseldorf. Röckelein was con-vinced of the advantages of this unit fromthe very first days of production.

The versatile lattice girder welding machinepermits both the rapid production of latticegirders in standard lengths and the tailor-made production of various types of latticegirders. Each individual lattice girder canbe manufactured with individual lengthsand heights. The height adjustment takesplace directly during production, just intime.

The steel for the lattice girder productioncomes off the coil. The wire is straightenedand fed to the welding machine. If the lat-tice girder parameters are changed, thesteel diameters for the top chord and thediagonal wires are changed automaticallyand without any retooling work. In the lat-tice girder processing centre the lattice gird-

Formwork pallet complete with reinforcement on the way to the con-creting station

The Kübat bucket track transfers the concrete to the Ebawe concretedistributor

The pallet complete with reinforcement is concreted precisely accord-ing to the element geometry by the automatic concrete distributor

Using the special lifting traverse the lattice girder slabs are lifted offthe pallet directly by the lattice girders.


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ers are produced either just in time and fed directly to the robotinstaller or produced ahead and stored intermediately in latticegirder magazines.In the further processing the lattice girders are cut to the respective-ly required length and then transferred to the supply magazine forthe robot installer.

Automatic production of the transverse reinforcement with automatic spacer fitting

The transverse reinforcement is drawn directly from coils, straight-ened and cut to length. Before the transverse reinforcement isplaced in position by the robot, the individual bars are fitted fullyautomatically with spacers. Three different types of spacers suitablefor a wire diameter of 6 mm and the respectively required concretecoverage are taken from three sorting pots and pushed onto thestraightened bars. The robot picks up a maximum of four transversebars and positions them in the appropriate places on the formworkpallet.

Multi-axis robot places lattice girders and longitudinal reinforcementThe production of the corresponding longitudinal reinforcement alsotakes place fully automatically with steel from the coil. The steel isprocessed by a straightening, cutting and bending machine of thetype MSR 16. The longitudinal reinforcement bars are temporarilybuffered in the upper level of a two-level supply magazine, whilethe lattice girders in the lower level are conveyed toward the form-work pallet via a chain magazine. The robot avails itself of bothmagazines and positions longitudinal reinforcement and lattice gird-ers directly on the pallet in the appropriate positions on the trans-verse reinforcement in accordance with the specifications.After the positioning of the reinforcement the complete 17.5-metre-long pallet drives out of the reinforcement station at the next cyclestep.

Concreting station with shaking and vibrating compactionThe concrete is discharged onto the formwork pallet by the auto-matic concrete distributor, which is fed by the Kübat concrete buck-et track. The special discharge system doses the concrete evenlyinto the areas enclosed by the formwork on the formwork palletaccording to the element contours and the required concrete thick-ness specified by the main computer.

Once the concrete has been completely poured, it is compacted inthe next work step in the same station in order to remove entrappedair and to ensure good grain size distribution. The shaking andvibrating compaction methods are available to Röckelein.

Drying chamberIn the next cycle step the pallets with the freshly concreted elementsare driven at floor level into the drying chamber for hardening. Thecomplete sequence of putting into and taking out of storage is han-dled by a fully automatic computer-controlled stacking crane. Foroptimal use of the floor space in the building, the pallets are stackedon top of one another in the rack system.

Within one cycle step the stacking crane puts one formwork palletinto storage and transfers a second pallet with hardened compo-nents to the discharge station. The pallets with the hardened latticegirder slabs drive automatically out of the drying chamber and canbe lifted off the formwork pallets by means of a lifting traverse.Several lattice girder slabs are stacked up inside the building andthen transported to the outdoor area by means of a run-off carriage.

BUCKET CONVEYOR SYSTEMSCONCRETE DISTRIBUTION SYSTEMS

Mono rail system rotary bucket Bucket with double flap gate

Two rail system rotary bucket Bucket with double flap gate

Semi portal frame distributor Inclined host

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Phone: +49 (0) 75 84/92 09-0Fax: +49 (0) 75 84/92 09-20E-Mail: [email protected]: www.kuebat.de

KÜBATFörderanlagen GmbHMax-Planck-Str. 14D-88361 Altshausen, GERMANY

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Plant concept was convincing from the first day of productionWith an intended output of up to 3000 m²of high-quality lattice girder slabs per dayin multi-shift operation, the new circulationplant at Röckelein is making a clear state-ment.

Apart from the impressive performancecapability of the circulation plant, Röckeleinalso emphasises in particular the signifi-cantly improved working conditions for itsemployees. Just as the relatively low noise

emissions avoid hearing damage throughprolonged exposure, the pleasant workingheights and support by cranes and robotsalso mean that there is considerably lessstress on the employees’ joints and backs.

However, environmental protection was alsoa major issue of the large-scale project atthe Rattelsdorf site. In the course of the con-struction of the new building, Röckelein notonly carried out extensive renaturationmeasures on the adjacent bank of the Main;photovoltaic systems are also planned forthe roof areas of the new building.

In conclusion, managing director WolfgangRöckelein sums up contentedly: ‘With thenew production plant we have set a mile-stone together!’ Hence, he praises not onlythe good interaction of the three supplierswith one another, but also and above allthe great dedication and flexibility of eachindividual supplier, which ultimately led tothe success of the project which was com-pleted in such a short time.

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FURTHER INFORMATION

Kaspar Röckelein KGBaustoffwerk EbingBamberger Str. 18196179 Rattelsdorf, GermanyT +49 9544 94900F +49 9544 [email protected]

EBAWE Anlagentechnik GmbHDübener Landstraße 5804838 Eilenburg, GermanyT +49 3423 6650F +49 3423 [email protected]

progress Maschinen & Automation AGJulius-Durst-Straße 10039042 Brixen, ItalyTel. +39 0472 979100Fax +39 0472 [email protected]

Liebherr-Mischtechnik GmbHIm Elchgrund 1288427 Bad Schussenried, GermanyT +49 7583 9490F +49 7583 949399 [email protected]

www.liebherr.com

Kübat Förderanlagen GmbHMax-Planck-Straße 1488361 Altshausen, GermanyT +49 7584 92090T +49 7584 [email protected]

Satisfied with the new lattice girder slab production plant: (from left) technical managerBernd Weber, managing director Wolfgang Röckelein and his son Christoph Röckelein

Kaspar Röckelein, founder of the family-owned company, also drops by the newproduction building for lattice girder slabsnow and again

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Kaspar Röckelein KG, 96179 Rattelsdorf, Germany Röckelein relocates its lattice ......

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