The Oschatz concrete plant banks on robot technology

In modern architecture, shapes, colors and surfaces are becoming increasingly varied. At the same time, the capacities required for construction projects are increasing, and cost pressure is rising. Machine technology and precast concrete production must keep up with this trend. Modernization is also a keyword at Oschatz Concrete Plant.

The tradition-rooted Oschatz  precast plant has been supplying prestigious construction projects with high-quality precast concrete parts for more than 25 years. During this period, the plant, established in 1995, has been modernized and upgraded several times to the latest technology standards. “Robot technology increasingly changes the way we work. Manual processes are automated, resulting in continuously rising plant capacities,” as Managing Director Birgit Zocher describes the processes involved. Oschatz is banking on the plant-engineering specialist Vollert as knowhow partner. Most recently, in 2012, new vacuum pallet turning equipment from Vollert was installed. In 2018 followed modernization of the formwork area as well as of the cleaning processes.
State-of-the art mechanical engineering, thought-through down to the smallest detail

 “Our highly efficient robot technology has been ensuring precision and clean, reliable processes since April,” explains Markus Schenk, Marketing Project Manager at Vollert. The latest Smart Set robot line has been placed in charge of fully automated and CAD-CAM-controlled demolding, and of plotting the contours for production of slab elements and double walls. In a subsequent step, at high traversing speeds, shuttering elements of various lengths are positioned with high precision. Likewise, component parts such as magnets for electrical outlets are set in place, with up to four magnets positioned simultaneously. Modern laser and camera systems monitor this process.

Also newly installed was a Smart Store magazine robot, which places shuttering elements in interim storage in the storage magazine. “With this new robot technology and our automated processes, we can move 5 to 6 rotating pallets per hour through this work area,” explains Birgit Zocher. “The individual robots, moreover, operate in separate safety areas so that work can continue even in the event of interference in one robot area.” “This presented a special challenge, given the shortage of space available – because, apart from the restricted floor area, a working platform for preparing the reinforcement lies directly above in some areas. But we were also able to find an optimal solution for this challenge,” concluded Markus Schenk.

A Smart Clean cleaning station was also newly installed

Furthermore newly installed was a Smart Clean station. Here, the Smart Set demolding robot takes up the shuttering profiles and places them on a roller conveyer on which they are moved to the formwork cleaner. Cleaning takes place in a conventional manner with disk and roller brushes.

Next follows application of release agent through spray nozzles. A pallet cleaner with rotating brushes and a steel scraper unit frees the surfaces from adhering concrete residues and adhesives. An integrated spray unit with rotating nozzles then automatically applies release agent to the sheet steel and the edge formwork as soon as the pallet travels into the work area.


Related articles:

Issue 04/2016 Vollert Anlagenbau

All in Precast – Bauma 2016

Under the theme ’All in Precast’, Vollert will be presenting new plant and machine concepts for stationary and fully automated production of precast concrete elements from April 11 to April 17 at...

Issue 08/2020

Kerkstoel 2000+ produces architectural precast concrete elements for highest demands

Kerkstoel 2000+ and Vollert in collaboration with Prilhofer Consulting have created a highlight in industrial series production of demanding architectural precast concrete elements in Belgium. A wide...

Issue 11/2016

Shanghai Baoye relies on advanced precast construction trechnology from Vollert

Precast technology has a long, nearly 60-year, tradition. In the absence of state subsidies and due to the low quality of the precast products manufactured at the time, the boom found a sudden end as...

Issue 06/2016

Thai SCG Group invests in modern precast ­concrete production­

In the future, up to 2,200,000 m² of solid concrete parts will be produced annually in Sarabury and Chonbury, to the north-east and south-east of Bangkok. For walls and slabs in grade A, premium...

Issue 10/2020

MyHome Group produces semi-finished precast elements for the Chinese construction boom

Based on a 5D-BIM solution and the highly automated industrial production of precast concrete elements, MyHome Group is accelerating the development of the trillion blue ocean market for prefabricated...