The JFI process is an innovation from Sommer Anlagentechnik and SAA Engineering, which has been patented in 2012. The process enables fully automated production of multi-layer concrete elements to highest precision with a high degree of flexibility and productivity and has been nominated for the bauma Innovation Prize 2013.
Previously, manufacture of multi-layer concrete elements largely took place manually, which is one of the reasons for its until now rather low market share. The manufacture of sandwich elements with curtain façades made of clinker, tiles, artificial or natural stone is labor intensive and inflexible.
Enhanced competitiveness of precast concrete components
The new process was developed for the requirements of the Russian market. But the considerable advantages it has for the manufacture of high-quality façade elements worldwide will increase the market share of precast components worldwide. The worldwide first plant equipped with the energy-efficient, highly productive and resources saving technology will be commissioned in larger Moscow in the middle of 2013.
New areas of application in the manufacture of complex precast concrete parts will open up and different construction projects can be cost-efficiently implemented. Energy and materials cost are reduced, e.g. by saving plastics templates and insulation materials. The possible use of different façade cladding materials, e.g. stone, steel, aluminum, ceramic, or photovoltaic elements will greatly enhance the technical and aesthetic quality of construction projects.
The fully-automated, CAD-supported production processes will increase the cost-efficiency of the production processes and improve the working conditions in plants as well as the competitiveness of precast concrete parts vis-à-vis in-situ concrete.
During the production process involving application of a joint compound, the filler is automatically applied to the surface of the production pallet in a grid according to CAD planning. The façade elements can be fixed in place and the edges of the formwork provided with a seal to enable compensation of tolerances.
In an additional production process, the façade cladding elements (tiles, clinker, etc.) are automatically conveyed to a transport and cutting plant and placed by robot exactly where required on the production pallet.
Furthermore, a production method for automatic feeding, cutting to size, drilling, positioning of the insulation layer, and automatic mounting of the wall connectors was developed. A set-up robot positions the panels on the freshly cast facing layer and subsequently mounts the wall connectors in the fresh concrete.