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Precast production line for the manufacture of slats and beams for pig farming installed in the US

Midwest plant
Midwest Dry Cast

Midwest Dry Cast, based in Luverne, Minnesota, is specialized in the manufacture of concrete products suitable for pig farms, like slats and beams. This young US company wanted to evolve into an industry of the future and decided to industrialize its productionAs a partner for this project, they chose Quadra, a French manufacturer of special machines. Quadra delivered a precast production line to meet Midwest’s high expectations in terms of productivity and product quality.

A new collaboration

To industrialize production, the choice of a partner was essential and risky for the company. For Midwest Dry Cast, this production unit project was born out of a desire to evolve into an industry of the future. In addition to productivity criteria and product quality, this plant was part of a global process of improvement and progress. This is how operators’ health and safety and environmental criteria were taken into account in the development of the project.

An innovative concept

The kinematics of the plant allows to use two molds at the same time. An automatic mold handling and movement system positions one mold at the manufacturing workstation while the other is installed at the finishing workstation. The following operations are carried out at the manufacturing workstation – placement of reinforcements, concrete filling and vibro compaction. While the following actions are happening at the finishing workstation – trowelling, demolding, and quality control. The production cycle is split into two phases of similar duration.

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AIR’BLOC IN SAINT-MAUDEZ: INAUGURATION OF A PLANT DEDICATED TO THE MANUFACTURE OF INNOVATIVE CONCRETE BLOCKS

Usine Air'bloc
Inauguration of a new plant dedicated to the manufacture of innovative concrete blocks

On October 21 and 22, 2020, the brand new Perin & Co. plant was inaugurated. Located in Saint Maudez, this facility is the 3rd Air’Bloc® plant.
established in France. In 2014 Perin & Cie will design and develop the Air’Bloc. It is the combination of a concrete block and an all-mineral cement-based insulating foam called Air’Mousse. To generate the insulation, Air’Mousse, patented by Perin & Co., a special filling machine must be installed. This machine is the result of a 3-year collaboration between Quadra and the Perin & Co. group.

Collaboration between Quadra and Perin & Company

As an industrial partner, Quadra participates in the development of Air’Bloc installations, provides innovative equipment, while improving existing production lines. As part of its new investment in Saint-Maudez, it was important for Perin & Co. that their partner was able to meet precise specifications. Thanks to its technical expertise and after an in-depth study of the various aspects of the project, Quadra was able to provide an appropriate response.

Plant layout

Given the particularity of the Air’Bloc® manufacturing process, the equipment was installed in a rational and functional manner. This layout allows each stage of the manufacturing process to operate simultaneously and continuously. With its different equipments, this versatile production unit can produce classic blocks, rectified blocks and high quality Air’Bloc®.

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State-of-the-art concrete block plant at Prefer in Belgium

Palettisation des produits secs

The installation of this new plant had to meet very precise specifications both in terms of production performance and product quality. To meet the group needs, Quadra presented a solution capable of ensuring continuous operation of the vibrating press.

To achieve a high efficiency rate, simultaneous or independent production cycles have been proposed for the fresh products, the dry products and the packaging line:

  • By ensuring at all times, the supply of the press with empty pallets to consume concrete continuously.
  • By pre-storing a large quantity of dry products pallets, thus avoiding the presence and systematic intervention of an operator.

The handling solutions offered and the automated management of materials favoring the continuous operation of the vibrating press are the reasons why PREFER decided to renew their confidence in QUADRA for this new project.

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Wetcast production line designed for the manufacture of manholes

Urvoy has chosen Quadra to supply a new wetcast production line for the manufacture of manholes using self-compacting concrete (SCC). The manufacruring process and the equipment were designed in order to meet the range of products manufactured in the line (manhole covers, risers, cones and bases), their dimensions (1m diameter, 300 to 1200 mm height), and their production features : cones and risers require a demolding by mold opening while covers and bases are demolded by flipping over.

This new production line has involved a 3D virtual reality reception in order to provide the client with a total immersion in his future plant, as well as an upstream work and validation of the ergonomic and the maintenance access of each working station of the process.

The production unit is made up of the following equipment : full automatic stacker crane, automated mold filling system, conveying system, demolding and palletizing cuber, and pallet exit conveyor.

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New production unit for the manufacture of innovative concrete blocks with high performance

During the last 10 years, the construction industry has been changing to technical products with high thermal, mechanical, acoustic, seismic and environmental performances. The concrete industry has been recently providing innovative products which combine technical reliability, aesthetic finishing, and easy implementation. These new products are largely approved by the manufacturers that are submitted to the new energetic and environmental regulations buildings. The concrete block is promoted, and regains market shares.

The company Pomel Beton, group Bomeil/Boulard Verdier since 2010, and member of the Groupement Gedimat, manufactures a large range of concrete products intended for industrial, residential, agricultural construction, and also used in the landscaping industry. Pomel Beton’s old production unit did not allow the manufacture of technical blocks or the use of new technologies. Therefore the group took on a strategic position in investing in technical installations provided by Quadra.

As part of this investment, the company Pomel Beton defined several specifications. More than a supplier, Pomel Beton was looking for a partner able to assist them in the manufacture of new value-added products such as a grinded block, and the insulation block “Air’Bloc’.

Following a strong investigation of all aspects of the project such as the existing environment, the current and future production requirements, and a rational implantation, Quadra provided the following equipment: batching and mixing plant, vibrating press, grinding machine, palletising robot, handling equipment, and dosing and filling system feeding the hollow block with a mineral foam for the manufacture of the product Air’Bloc.

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Fabemi invests in a new model of vibrating press with high production capacity

The quality and the manufacturing excellence are the particular strengths of the group that focus on using the best manufacturing technologies. Following the realisation of manu projects with the manufacturer of Equipment Quadra, Fabemi renewed its confidence in his partner with the modernisation of its plant of hight capacity of production. The technical challenge perfectly taken up by Quadra was the integration of a new generation vibrating press within an existing plant, in reusing some Equipment.

The thorough study and in-depth analyse carried out by Quadra enabled the new block machine to manufacture a volume of production that was never reached, without being disturbed or slowed by the other Equipment. In order to make use of the performance of the block machine, Quadra has recommended to replace the traditional palletising equipment with a modern Equipment fully automated and robotized and removing all the hydraulic functions. This new cubing line consists of three robots operating simultaneously, following the cycle time of the vibrating press, within operating condition combining precision, speed, flexbility and reliability.

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Launch of a new interface: measurement, evaluation and characterization of vibration

It’s widely agreed that the perfromance of the concrete, particularly in terms o f mechanical resistance and sustainability, comes from the quality of the vibration during the mfanufacture of the fresh concrete. Quality vibration ensures a concrete with uniform composition and guarantees a global homogeneity of the material overall. The current challenge in manufacturing concrete products is reducing the manufacturing cycle time while improving the quality of the product, enhancing the sustainability of the materials and assuring consistency of production. Controlling vibration and its effects on product quality and speed of production are crutical in the concrete industry today.

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Fully customized and automated cubing of concrete products

The manufacturer Basalite provides complete product lines including structural block, interlocking paving stones, wall systems, ornamental and garden products with customized shapes, sizes, colors and finishes, and are renowned for their durability, sustainability and beauty. This focus on customization and quality led Basalite to the Equipment manufacturer Quadra. Having opened its US subsidiary in 2016, […]

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The manufacture of wet-ast gravel boards : high performance, state-of-the-art production plant

With a large range of colours, formats, structures and finishes, the gravel boards market is growing in the modern landscading industry. Maes Betonfabriek, based in Dessel, Belgium, is one of the main manufacturers of concrete fencing in the country. Founded in 1949 by Karel Maes, this family-owned company is currently managed by his sones, Lund and Dirk Maes, and the upcoming generation is already active in the company. With more than 50 years of experience, Maes Betonfabriek manufactures and markets a large range of concrete products.

The strong suit of the company is the sustainability, variety and contemporary design of its products. With a daily production of about 200 tons of concrete, Maes Betonfabriek is equipped with 4 wet-cast production lines supplied by Quadra, the Equipment manufacturer. The partnership between both companies began with the delivery of the first DIFAL machine in 2006. Faced with the technical and aesthetic requirements of the products and the growth of the business, Maes Betonfabriek quickly became interested in a modern, automated and efficient industrial solution, designed and manufactured by Quadra.

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Fully automatic wetcast stone

A family-owned company based in the South of France, Fabemi has been combining know-how and innovation since 1961, making it one of the most important players within the French market. With 14 plants spread throughout France, the Fabemi Group has been expanding its production thanks to innovative technology. Initially, Fabemi was known for the manufacturing of concrete blocks. Since then, the group has widened its production. Under the brand names Bradstone and Carré d’Arc, Fabemi currently produces and delivers a large range of wetcast products designed for the landscaping market: slabs, pavers, copingstones and garden products, retaining walls, and wall coverings.

In order to boost its competitiveness, enhance the quality of its products and avoid repetitive and painful tasks for its operators, Fabemi has invested in the full automation of the production line based in Donzere and exclusively dedicated to the manufacture of wetcast products. To achieve this technological leap Fabemi has established a partnership with the French equipment manufacturer Quadra. Currently, only 4 operators manage the complete production process, from the mould cleaning, oil application and concrete filling through to the curing, demoulding and palletizing of the finished product. Equipped with a modern handling system, the plant is fully automated and achieves high versatility. All the items of equipment provided have the ability to adapt their system to the multiple product formats. This is the main innovation. To do so, an RFID chip is integrated in every pallet and identifies the type of the product. Accordingly, this RFID chip controls the oiling settings, the concrete dosing, the automatic introduction of balls on the back of the products, the product reference printing, and the demoulding and palletizing conditions with high precision.

This innovative system was developed and implemented by the supplier Quadra. This is a unique process, since up to now no device has been able to adapt to successive and changing mould formats in real time. More than 4000 manufacturing recipes are recorded, handled and automatically incremented. The production line and all stations permanently and automatically switch into all recipes .