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Short cycle time plus outstanding product quality: key arguments for commissioning a new plant in England

The Maen Karne Group is made up of Maen Karne Aggregates Ltd and Maen Karne Concrete Products (formerly Western Blocks Ltd). Recently acquired by the GRS Group, the Maen Karne Group has displayed sustained growth since its founding and is now one of the leading renowned suppliers to the precast industry in the southwest of the UK. The Maen Karne Group is active in several fields: supply of aggregates, manufacture of ready-mix and precast concrete, manufacture of concrete products (mainly blocks and pavers) and the supply of waste management solutions. Divided into four sites and equipped with two plants for the manufacture of concrete blocks, Maen Karne placed an order with Quadra for the upgrading of the existing production line and commissioning of a “high performance” block making machine at their Melbur site, located in the county of Cornwall. High production capacity, consistent and optimum quality in terms of height, compaction, durability and dimensions, and ease of maintenance - these were the main requirements for the new plant. The wealth of experience and proven skills of Quadra have finally convinced the Maen Karne Group, which has chosen to rely on the French equipment and know-how.

Bespoke block making machine designed for manufacturing hemp blocks

Located in Etalans in the east of France, Vieille Matériaux was founded in 1963 by René Vieille. Currently headed by his grandson, Sebastien Vieille, this family-owned company
has been specializing in the manufacture and trading of precast concrete products for more than 60 years. Recognized throughout its area for the quality of its products and
its ability to innovate, Vieille Matériaux achieved a resounding success with the launch of its insulating blocks called “NRJ block” and their high thermal and acoustic performance.
Vieille Materiaux is continuing to grow and has expanded its product range with the manufacture of hemp blocks called “Biosys”. This is a special building solution
with a globally unique product, mechanically assembled when it is dry, with a high-precision vertical and horizontal interlocking system allowing fast and simple use. With the launch of this product Vieille Materiaux invested in its production equipment and has commissioned Quadra, a leading French manufacturer of equipment for the concrete industry. In fact, this new product has involved the building of a complete plant based in Mérey-sous-Montrond, dedicated to the manufacture of this product.

Wet-cast production line installed in Romania : a versatile & efficient plant

The Star Stone Company was founded by Cristian Pop in 2007. Specializing in the production of wet-cast products (slabs, pavers, concrete reconstituted stone and any kind of landscaping products), Star Stone has been growing exponentially since its beginning. Cristian Pop has recently decided to reach a new level by upgrading the plant. The continuing growth of Star Stone involves a high level of performance, which its existing facilities are not able to satisfy. Rather than a supplier, Star Stone was actually looking for a fully-fledged partner for proposing a new manufacturing solution: a major change for this manufacturer, who was basically manufacturing its products manually. Following a first contact during the Batimat show in 2011, where the manufacturer Quadra is always present, Star Stone took a closer look at Quadra by visiting several plants and studying the different technologies that might be applied for automating its production.

New concept of vibrating press with semi-dry demoulding by turning over: manufacturing of manholes & a large diversity of products

Created in 1988 by Mr Pascal Leandri, the company Prefabeton, based on the island of Reunion in France, is specialised in precast concrete products designed for road works, building, construction and public works. Prefabeton has successfully ensured its leading position by investing in effective production equipment. The leading manufacturer within its area, Prefabeton has enlarged its products range over the years: slabs, pavers and kerbstones with high added value, blocks, vegetative retaining walls, manholes, gutters, rainwater scuppers and other concrete products designed for companies, craftsmen, municipalities and private individuals. In 1997, Prefabeton became the first
company on the island of Reunion to obtain the standard called “NF” for its manhole range. This quality process is now applied to all its products, along with CE branding in order to provide its customers with certified products. The first collaboration between Prefabeton and Quadra was in 1999 when Prefabeton bought their first production unit with block machine. This long-standing client has recently commissioned the equipment manufacturer Quadra with a large-scale project: the manufacturing of solid products with semi-dry demoulding by turning over, through a fully-automated process. This production was originally ensured by its operators working on machine type vibrating tables or small rollover machines. The main production for which this new equipment was intended was the manufacturing of manholes and seating rings and extended to other products such as low walls, retaining building blocks, drainage channels and other products with suitable dimensions for the curing chambers