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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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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.

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Performance, product quality and flexibility: vibrating press of high capacity set-up in Dominican Republic

Renowned for combining high-quality products and product innovation, the company BC Suplidora, manufacturer of concrete products, has been a key player in the Dominican Republic. Based in Santo Domingo, BC Suplidora has decided to increase and upgrade its production facilities in order to cater to a fast-growing market. This manufacturer was looking for a supplier able to assist the company in the achievement of its ambitious objectives in terms of performance and production capacities. BC Suplidora commissioned the French equipment manufacturer Quadra to install a complete production plant, fully automated, including the latest technological advances. The requirements were related to the flexibility, the performance and the efficiency of the equipment provided, with a view to outperforming and offering further enhanced products, and efficiently meeting the growing needs of the customers. The new production unit was also the opportunity to enable BC Suplidorato to extend its range of products. BC Suplidora aims to specialize in the production of concrete kerbstones and to position the company as one of the pioneering manufacturers on the island for this type of product.

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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.

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New concept of vibrating press with semi-dry demoulding by turning over: manufacturing of manholes & a large diversity of products – equipment commissioned in Reunion Island

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.

 

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A multi-skill partner: commissioning a high-performance block making machine and a fully-automatic precast production line

Since 1954, Celtys, a subsidiary of the Quéguinier Group and based in Brittany, France, has been developing, manufacturing and selling a large range of concrete products designed for the construction and the landscaping industries. With 4 plants in operation, Celtys has been relying on its experience and its standing as one of the leading suppliers in the French market boasting a daily production that exceeds 1,000 tons of products. ISO 9000 certified since 1993, Celtys has been building its growth and reputation on a specific quality approach system in order to provide its customers with products that comply with these standards in terms of reliability, safety and environmental protection aspects. In fact, the company’s product range offers numerous advantages in terms of aestheticism, product features and sustainability that enable Celtys to accompany any kind of project – from the simplest to the most advanced.

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Reference turnkey plant in Saudi Arabia: a versatile, multi-purpose and multi-product solution

The company Steeco, based in Ryiadh, is currently managed by Suliman Al-Turki and has managed to achieve a strong positioning in the precast industry in Saudi Arabia. Renowned for combining high quality product and regular product innovation, this manufacturer has experienced an exponential growth through continued expansion of its product line. As innovative manufacturer, Steeco regularly invests in its production equipment in view of enhancing its manufacturing process as well as launching new product on the construction and landscaping market in constantly evolving. Steeco manufactures concrete blocks, paving stones and kerbstones within multiple format and color. Thiscompany has sollicited for the first time the equipment manufacturer Quadra in 2010. Equipped with a basic mobile machine at this time, Steeco makes a first step by commissioning an automatic production line including an efficient block machine type Q6. Fully satisfied with the production outputs, and convinced in the reliability and the performance of the equipment provided by the french leader in the manufacturing of concrete production equipment, Steeco further develops its influence and makes a new bold decision by entrusting once again Quadra for the planning, the manufacturing and the commisionning of a new large-scale full plant.

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State-of-the-art concrete block production facility

All concrete plants of Chausson Matériaux are equipped with production units made by Quadra, and a new partnership was signed between these two companies for the design, engineering and commissioning of a new full-scale plant located at Cavaillon in southern France.

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Fully Automated mould change in a block machine: new patented system

To meet the requirements of the market, a key concern for the concrete manufacturer is to succeed in reconciling flexibility, productivity and safety, while offering an ever-larger range of high-quality products. It is known that manufacturing plants produce according to their stock and the specific orders they receive. However, quantities and type of product are increasingly variable. In order to react to their customers’ wishes, concrete manufacturers have to change their production several times during a shift. However, this operation has a big impact on the production. On the one hand, the overall manufacturing process is affected in that the production changeover involves a production shutdown which adversely affects the rate of production. On the other hand, this operation affects the labour force during the handling of moulds, exposing them to hazards and frequent work-related accidents.