Double wall0 pages

06b-Fertigteile_170-203_en.qxp:Layout 1

11.11.2011

12:33 Uhr

Seite 192

PRECAST CONCRETE ELEMENTS
Vollert Anlagenbau GmbH, 74189 Weinsberg, Germany

The new CDLP precast plant in France impresses
by its compact plant structure and intelligent work
processes
The French precast concrete element manufacturer CDLP recently put its new production plant in Pontcharra near Grenoble into operation.
Up to 110,000 m2 of floor slabs and 110,000 m2 of double walls will be produced here annually on a modern pallet circulation plant in
2-shift operation. The plant equipment was supplied by the concrete works specialist Vollert Anlagenbau, which faced a particular challenge
in the implementation, especially with regard to the compact plant structure and intelligently conceived work processes.
The limited spatial conditions on the CDLP
works site in Pontcharra, France, presented
a particular challenge for the layout of the
new production plant for floor slabs and
double walls, above all due to the fact that
the planned pallet circulation plant was to
be erected in an already existing factory
building. In order to be able to produce
precast concrete elements economically
and to be able to react flexibly to fluctuating demands, CDLP focused from the outset
on a sustainable plant concept with flexible
work processes that had been thought out
to the end. The plant, which was completed
at the end of June 2011, is therefore tailored
precisely to the environmental conditions
and to the precast concrete elements to be
produced.

Compact plant structure and economical
work processes
CDLP selected an experienced plant constructor for this project that could not only
deliver the know-how and the technology,
but which was also able above all to coor-

dinate the production processes precisely
to the particular spatial conditions and the
required production numbers. Under the
technical project leadership of Dipl.-Wirt.Ing. Björn Brandt, and on the basis of 3-D
planning models, Vollert Anlagenbau from
Weinsberg developed various scenarios
that were presented to CDLP in project meetings in order to make the decision on the
most economical plant concept transparent
and to bring it about.
Based on an average capacity of the production plant, a semi-automated pallet circulation plant was chosen on which untensioned floor slabs and double walls are
manufactured. “28 formwork pallets circulate constantly, which ensures considerably
more efficient production processes and
thus higher plant productivity in comparison
with stationary production”, explains
Brandt. “This procedure enables machines,
aids and materials to be used in the right
place and thus to increase the quantity and
quality of production whilst at the same time
reducing manufacturing costs.” Thanks to its
compact plant structure, the pallet circula-

Pallet circulation plant for 110,000 m2 of floor slabs and 110,000 m2 of double walls
annually

192

CPI – Concrete Plant International – 6 | 2011

Philippe Marrié studied civil engineering
at the University of Applied Sciences in
Constance (gaining degrees in civil engineering and industrial engineering) and has
over ten years of experience in the precast
concrete element sector. Following tenures
in a technical consultancy and as production manager at various
precast works, he worked for several years at Reymann
Technik as a project leader both in and outside Europe. He has
been employed as a project manager at Vollert Anlagenbau
GmbH since 2009.
philippe.marrie@vollert.de

ting plant has a footprint of 100 x 25 m.
110,000 m2 of floor slabs and 110,000 m2
of double walls (a total formwork area of
330,000 m2) will be produced annually in
future in a 2-shift system.

Modern plant technology ensures
high productivity
The formwork pallets are cleaned first of all.
In the first work process a fully automatic
CPR device (Cleaner, Plotter, Release agent
application) frees the pallets from adhering
concrete residues and adhesives by means
of rotating brushes and steel scrapers. In
the second work process the CPR device
automatically sprays the pallet with release
agent. Rotary nozzles were used in order to
do justice to the aspect of economical
dealing with operating resources and to
ensure even application of the release
agent. The rotary nozzles make it possible
at any time to adapt the discharge individually in relation to the viscosity of the
release agent. In the last work process of
the CPR device, the plotter draws the precast concrete elements to be produced on
the formwork surface on a 1:1 scale. In
order to obtain the desired application
accuracy of + 1 mm, the pallet is centred
pneumatically at the CPR position from
below by two cylinders. Once the centring
has been released again, the pallet moves
on roller blocks driven by friction wheels to
the manual formwork positioning. Further
development of even the simplest compowww.cpi-worldwide.com