Elematic Oy Ab, 37801 Toijala, Finland Complete precast ... · ject in Riyadh, along with several...

CPI – Concrete Plant International – 5 | 2010 www.cpi-worldwide.com168

PRECAST CONCRETE ELEMENTS

With a clever concrete distribution system, Al Fanar is able to serve all production halls very quickly and in time with fresh concrete

Satu Jussila, Helsinki, Finland

In September 2008, Elematic and Al FanarCo. Ltd. signed an agreement for the deli-very of a complete precast factory in a new

industrial area very near to the city of Ri -yadh, in Saudi Arabia. It is located southtowards Al Kharj by using the eastern RingRoad. The factory was built and running inNovember 2009. Final acceptance was inJanuary 2010, and between November2009 and January 2010, small adjust-ments were made and production controlundertaken. “After signing the agreement, it took onlynine months when we started production inthe batching and mixing plant and with thefirst hollow-core casting beds. This was real-ly fast for a project this huge,” confides Kim -mo Vesterinen, Export Manager, Elematic’sSales Department.In total, the entire factory was up and run-ning 14 months after signing the agree-ment, which, explains Vesterinen, was pos-sible as a result of close teamwork. “Bothsides had to inform each other every weekabout the status of the project in order tocontrol the timeline and act immediately ifthere were abnormalities in the agreedschedule.” Markus Hennig, Al Fanar’s Factory Mana -ger, also mentions that partnership was apriority. “For this short time schedule, youcan complete the project only with 100 per-cent effort from all parties,” says Hennig.

“Civil-work quality issue and time scheduleproblems, machine delivery schedules,installation mistakes, manpower and mate-rial availability – detailed coordination bet-ween the parties is needed.”

Scope of products delivered

Elematic’s delivery involved construction ofa plant for the manufacturing of all precastcomponents needed in buildings: hollow-core slabs, facades and grey walls, andcolumns and beams. The entire factoryarea is 122,000 square meters and theproduction area 25,000 square meters. Itincludes the B&M plant, element storage,aggregate storage and facility buildings.

Hardware consists of two extruder-basedhollow-core slab lines, each 8 x 150 meterslong with extruder, saw, BedMaster, cove-ring system and lifting beams for the manu-facture of 150, 200, 250, 300, 350, 400and 500 hollow-core slabs and for thewalls and facades in an ELSA line (inclu-ding an Elematic FaMe Flex system andplotting machine). It has a combination ofcirculation line and cross-transfer beamswith curing chamber. FaMe aluminum pro-files with magnets are used to make theshuttering for elements.

Complete precast factory sold to Al Fanarin Saudi Arabia

Elematic Oy Ab, 37801 Toijala, Finland

For Elematic and Al Fanar, delivery of a complete precast factory was on a fast timeline from start to finish. The plant produces hollow-coreslabs, wall and facade elements, concrete beams and columns, and other custom-made special elements to meet the growing needs.

In the beginning of 2010, the new Al FanarPrecast Plant was taken into operation

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SRL

Via G. Di Vittorio, 42 - Fornovo di Taro (Parma) - ItalyTel: +39 0525 400511 Fax: +39 0525 400512

[email protected]

w w w. b i a n c h i c a s s e f o r m e. i t

Mouldsfor Precast elements

Civil Buildings

Industrial Buildings

Bridges and Viaducts

Comcasters are used to cast the elements. Hydraulic tilting molds forspecial products, TT-molds, and beam and column molds are alsoincluded, as well as concrete distribution system. Additionally, thefacility has laboratory equipment.The plant uses a casting skip at the moment for casting beams in aSkeleton casting bed. The Skeleton casting bed includes a beambed with side walls and pre-stressing abutments. ELiPLAN enterpriseresource planning software is used (ELiMIX for the B&M plant andELiLINE for the circulation line).

The concrete bucket conveyors are serving the production linesfor TT-molds, wall panels, hollow core slabs and all other kindof precast elements




Timeline schedule from start to finish

While the Al Fanar plant was a big project,and the timetable was challenging alreadyfrom the beginning, it followed the samesteps that Elematic uses for other projects.Briefly put, the main mileposts were achie-ved in the following order:

· Elematic’s technical team meets withAl Fanar to check all details

· Customer builds factory foundation andinfrastructure work, while Elematic manu-factures the equipment in Finland

· Elematic transports machinery to SaudiArabia by sea freight

· Machines are installed together with

the customer’s technicians · Equipment is ready for test production

and, simultaneously, Elematic trains alloperators

All infrastructures, including water, electri -city and inside roads, were self-organizedby Al Fanar. Only the main connectionroad was built beforehand. After signing

Besides the Elematic EL900E Extruder, Al Fanar is using a Bedmaster and an EL1300A saw from Elematic for the hollow core production lines

Using formliners and the Elematic FaMe system for the molds, Al Fanar are producing architectural wall systems




the contract with Elematic in September 2008, Al Fanar startedplanning for the plant. Land-area leveling was made in Novemberand excavating started in De cember. The first columns were erectedin February 2009. In the beginning of April 2009, the founda tionof the HC-bay 2 and B&M plant was ready for installation of machi-nery. During this time, Elematic made basic information drawings, machi-nery design, manufacturing and shipping. The first machines were atthe site with erection drawings by mid-March. Erections were start-ed in the beginning of April and priority was to finish HC- bay 2,B&M plant and concrete transportation between plant and bay 2. The testing of the B&M plant started in the second week of July andthe first quality HC-slabs were made on 25 July. Since that date, HC-bay 2 has made quality product. After that, it took three months tofinish the factory including circulation line, aggregate storage area,Skeleton beam casting bed, TT-molds, concrete transportation to allbays, and storage area for elements with the transport system.

Plant production moves forward

The Al Fanar plant was now producing HC-slab, columns and someother special elements. After 12 months from signing, the factoryand production was running. Du ring the next two months, Elematicand Al Fanar made production planning and some fine-tuning.“Designing and manufacturing of machinery were made in shortorder,” recalls Juhani Sivenius, Project Manager from Elematic’sside.“Elematic put effort into good scheduling for the manufacturing.Shipping of all goods was also challenging, because it was depen-dent on the finishing of manufacturing,” he adds. Installationsmoved forward rapidly. “From Al Fanar, we needed the foundation

Al Fanar is producing different kind of architectural wall panels

SRL

Via G. Di Vittorio, 42 - Fornovo di Taro (Parma) - ItalyTel: +39 0525 400511 Fax: +39 0525 400512

[email protected]

w w w. b i a n c h i c a s s e f o r m e. i t

Accessoriesfor Precast elements

Magnets andmagneticsystems

ConcreteDistributing

Machine

Lifting Equipment

AnchorsChannel

Vibrators




for machinery, and they pushed parties along so that installationflow was not affected. Al Fanar made sure that subcontractors wereon-time.” In a project of this scale, there are bound to be obstacles,“but the key is to solve them fast and move on,” feels Sivenius. “Withgood cooperation, we finished the project in a timely manner.”

Growing demands in Saudi Arabia

Al Fanar is a multi-industry company engaged in the manufacturingof electrical components, construction, building material in dustry,real estate development, informa tion technology and communication,indus trial ventures and investments. With the new investment inPrecast, the company enhances its operation into the building materialindustry. The plant capacity is 200,000 m3 per year. Deliveries are antici-pated mainly for go vern ment projects, such as universities, schoolsand villa projects, and also for the private sector. Precast is used ina multitude of sectors in Saudi Arabia – from high-rise buildings,luxury and low-cost villas, shopping malls, offices, car parks,bridges and railways. At the moment, there is a big university pro-ject in Riyadh, along with several villa projects over the Kingdom,and different financial districts under construction. School and hos-pital projects are also planned in the near future.The Saudi market has several companies that produce a full-rangeof precast elements. But there is enough work for all players andsome extra capacity is needed in some sectors to fulfill the marketdemand.

“We chose to invest in precast in order to satisfy clients with delive-ries in-time to guarantee the project time schedule and finish date,”says Mohammed Al Bayati, Division Manager in Al Fanar BuildingSystems Factory. “We also want to meet their high quality expecta-tions at a comparable price.”

Meeting the customer’s aftercare needs

Elematic has a service agreement that includes Elematic engineersvisiting Al Fanar’s precast factory on a regular basis. Custo mer ser-vice engineers will assist with production challenges, quality issues,operator training and maintenance. Additionally, Elematic has a sales office and warehouse in Dubaithat services the area and can supply spare parts. Sales peoplealso visit the factory to see how the customer is doing and to enquireif help is needed in daily operations. Elematic has a HelpDesk tele-phone line that is open for urgent matters.Elematic presence in the Middle Eastern dates back to 1976.Precast plants delivered by Elematic in recent years to meet the con-

Al Fanar is serving the market in Saudi Arabia with excellent pre-cast elements

Handling of the elements on the stockyard takes place by specialtrolleys and gantry cranes, as well




Via Foscarini, 45

31040 Nervesa della Battaglia (TV) - ITALY

Tel. +39 0422 725769 - [email protected]

www.socometspa.it

Our products for the prefabrication:

Vibrating-press with tilting system

Machines and vibrating systems

Plants for the handling, the curing and the

packaging

Storehouse for the curing

Automation of the production processes

Uffici e Stabilimento

Technologies for the concrete

FURTHER INFORMATION

Al FanarRiyadh P.O Box 301 · Riyadh 11411, Kingdom of Saudi ArabiaT +966 1 2755999 · F +966 1 2756699 [email protected] · www.alfanar.com · www.alfanarprecastconcrete.com

Elematic Oy AbAirolantie 2 · P.O. Box 33 · 37801 Toijala, FinlandT +358 3 549511 · F +358 3 [email protected] · www.elematic.com

struction boom include to Saudi Arabia, United Arab Emirates,Bahrain and Qatar. “We chose to work with Elematic because theyoffered a turn-key option with one supplier. Also, they have a goodreputation and references in the Saudi market and Middle East,”comments Al Bayati.The feeling of goodwill is also shared by Elematic. “Thanks to AlFanar for their professional leading team, we completed this projectsmoothly,” comments Sivenius.“The reason why this kind of timetable is possible is the fact thatAlfanar has an extremely good and effective organization,” addsVesterinen, noting “and they gave a lot of support to Elematic when-ever needed.”

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