Fully automated reinforcing mesh production based on ... · PDF fileTekla Structures, precast...

CPI – Concrete Plant International – 4 | 2012 www.cpi-worldwide.com186

PRECAST CONCRETE ELEMENTS

Mark Küppers, CPI worldwide, Germany

Those entrusting their construction project toHurks are assured excellent aesthetics,quality and individuality. Numerous refer-ence projects, some of which have beenawarded prizes, speak for themselves. Inaddition to the high-class quality of its pre-cast with their attractive surfaces, the com-pany has also made its mark with flexiblesolutions in the execution of construction

work. One such example is the new con-struction of a hospital building in Rotterdam.Due to the confined space conditions,Hurks decided to use a field factory whichgrew in stages along with the building. Allthe concrete elements were manufacturedon the floor on which they were needed.This rather unorthodox solution enabledconstruction to progress rapidly under over-all difficult conditions.

Hurks’ solutions to construction assignmentsdo not just enjoy great popularity in TheNetherlands. The company’s major marketsare located across borders from London toParis. Hurks scores particularly highly inrespect of special structures. The firm offers“turnkey” prisons made in a modular con-struction method, of which it has alreadybuilt 15 units in England alone. Other pri-sons made from Hurks precast can befound in Belgium and The Netherlands.

Fully automated reinforcing mesh production basedon design office 3D models

Hurks Prefabbeton BV, 5500 AE Veldhoven, The Netherlands

Large and complex buildings made from precast concrete components – these are just the type of construction projects where the strengthsof Hurks, a family business, can come fully into play. Backing up the Hurks name is a group made up of 15 companies with their head officein Eindhoven, The Netherlands. The Hurks Group is mainly engaged in the fields of planning projects, constructing residential and commer-cial buildings as well as manufacturing precast concrete components. Of a total of four construction companies belonging to the group, thetwo larger units plus the two precast production facilities are the main pillars on which the group is built. The 800 employees at the HurksGroup generate an annual turnover of € 280 million. Hurks provides a one-stop solution for everything. From the initial planning stage to the completion of a construction project, the companyaims to be the sole point of contact for the customer. There are practically no limits set to customers’ individual wishes both at home andabroad. The precast for all their construction projects are manufactured in Hurks’ own Prefabbeton precast production facilities in Tilburgand in Veldhoven close to Eindhoven. Hurks has quite recently invested in extensive modernisation of the reinforcing mesh production line at the Veldhoven facility. ProgressMaschinen & Automation AG from Brixen, Italy, has implemented a modern system concept that, besides welding individual reinforcing mes-hes from single bars, makes it possible subsequently to bend the meshes as well. The new production system accesses the data necessaryfor this fully automated manufacturing process directly from its database solution developed by Tekla Structures. Tekla’s software for creatingand managing detailed 3D models able to be used in design work has been employed by Hurks for years to the company’s full satisfaction.

Reference project made by Hurks inAmsterdam

The precast installed in Amsterdam had already been furnished with brickwork facing at theproduction facility. Hurks developed a special formwork system for this purpose

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High flexibility, rapidity and just-in-time production are key featureswith this innovative group of companies. A joinery for all types ofwoodwork, a steel structure department plus a reinforcement pro-duction line have all been integrated into the precast manufacturingfacility. In the first place, this makes Hurks more independent ofother suppliers. Added to this, it means that individual solutions,such as special formwork, can be manufactured at short notice.

Hurks has set itself very tight limits when producing precast. Itsmethod for prefabricating the precast components does not allowfor errors, which then have to be laboriously rectified during assem-bly. Hurks aims to rigorously exclude errors during both planningand production by means of appropriate measures. Noteworthymeasures include, for example, investment in a new reinforcingmesh production line, and a straightening-cutting-bending systemthat can handle wire up to a diameter of 20 mm, plus an automat-ed stirrup machine – all from Progress. In the past, reinforcementwas produced externally and bought in. Besides the delivery timesand the price being too high, the quality also sometimes gave par-ticular cause for concern.

One further improvement measure was the complete transition tosoftware from Tekla. Their partner in this changeover to the new soft-ware was Construsoft from Zevenaar, a Dutch company that workstogether exclusively with Tekla.

With a view to achieving a seamless data flow between the Teklasoftware and the new Progress machines, Hurks took the initiative ofbringing all three parties to one table. In common accord, the opti-mum solution for the interface between the Tekla and Progress soft-New hospital building in Rotterdam; the precast components were

continually manufactured in the superimposed field factory



ware was sought and found. This enablesthe machines on the production line to becontrolled directly with data from the mod-els generated by Tekla Structures.

3D modelling on the computer caught onrapidly at Hurks

The concrete construction industry isincreasingly changing over to using 3Dmodelling tools. Enhanced productivity, onaccount of more effective detailing andmanufacturing processes, is one majoradvantage in producing precast in this way.Such efficiency results in elements being

manufactured on schedule and being deli-vered as a custom-fit solution. Tekla develops and markets software solu-tions for civil engineering, infrastructuremanagement and energy supply. TeklaStructures, the software solution employedat Hurks, streamlines the entire workflow:beginning with sales, preparation of quota-tions, cost estimates and conceptual designright up to the planning and manufacturingstages including implementation and fol-low-up measures. Tekla Structures is modern Building Infor -mation Modelling (BIM) software offeringprecise and dynamic 3D surroundings inde-

pendently of both material and design com-plexity. Tekla Structures models can beutilised to cover the entire constructionprocess from conceptual design throughmanufacture and assembly right up to con-struction management. With the aid ofTekla Structures, precast components canbe easily combined with other buildingmaterials, such as steel and reinforced con-crete. This contributes to project manage-ment efficiency and flawless interworking.The Hurks Delphi Engineering office is alsoa company belonging to the Hurks Groupand is located at the same address asHurks Prefabbeton in Veldhoven. Hurks

Office and residential building in Den Haag

Hurks construction site in Ypenburg 3D model of the building designed by Tekla All design details can be selected from anyperspective desired with the Tekla software.Data ascertained from the 3D models formsthe basis for controlling machines on theproduction line

Hurks was awarded an architecture prize in 2008 for this building with its attractive precastfacing concrete wall elements



www.cpi-worldwide.com CPI – Concrete Plant International – 4 | 2012 189


Delphi Engineering generally only works for Hurks Prefabbeton. Atotal of 30 employees plan and design future building structures ontheir computers. This is now already the seventh year, in whichTekla’s software system has been employed exclusively there. Theengineers can design an entire building structure as a 3D model,from which all relevant details for the building’s execution can beretrieved.

Data concerning the models generated with Tekla is collected in acentral database. Despite the proliferation of models, the databaseremains relatively small and can thus be accessed readily. This data-base, made up of models, is also the basis for directly controllingthe machines on the production line. Hurks can see a real benefitwith the Tekla system in that many engineers are able to work on aproject simultaneously given the possibility of accessing a commondatabase at all times.

Tekla is the basis for all manufacturing at Hurks Prefabbeton andwas coupled up with the ERP system. Adopting Tekla software hasresulted in appreciable advantages over the competition for thecompany and it is very satisfied with the software from its partner.Hurks highlights the advantages of Tekla being both suited to massproduction as well as to custom-manufacturing individual concreteconstruction components. The company’s objective was to achievea higher degree of automation with the resultant savings on costs.

The Tekla Structures database is open and can be edited. Thismeans great flexibility in daily tasks with Tekla Structures.

Individual reinforcing mesh production based on Tekla models

Once working with Tekla software had been mastered at Hurks, anextensive modernisation of the reinforcement production line wasplanned. The two first investments in machine technology for pro-cessing concrete steel reinforcing were an MSR 20 2BK straighten-ing-cutting-bending system and an EBA S 16 automated stirrupmachine – both from Progress -, which perform their duty in anentirely satisfactory manner at Hurks. The company had been looking for a simple system with a very highdegree of automation that could transpose precisely the reinforce-

BIM model of a multi-storey car park with an area of 50,000 m²; allinformation is stored in the Tekla database, from which precise datais generated for the machine production line, ERP and assemblyplanning

Information concerning status and workflow is available to all thosetaking part in a project with BIMsight software free of charge fromTekla for model based project collaboration

Detailed section of the car park model; thanks to the Multi-UserMode, four or more users can work simultaneously with a commondatabase on a model at Hurks. This reduces the lead times in plan-ning substantially

The open API with Tekla Structures assisted Hurks in developing itsown programme components. For sandwich elements, componentswere developed with the required functional features in order toaccelerate modelling at Hurks. The Progress machines can run auto-matically with this data from the reinforcement models. The model-ling tools possess their own control function with a view to optimisingthe automated manufacturing process

Design details are more clearly populated in one model displayingall construction materials. Such descriptive illustrations help to pre-vent any possible design conflicts in the planning stage




There are almost no limits set to designing surfaces at Hurks Completed concrete wall elements have already been furnished withwindows etc. in the production facility

The MSR 20 2BK cutting and bending machine straightens, cuts andbends wire up to a 20 mm diameter from a coil. In addition, Hurksalso has a series EBA S automated stirrup machine

Construction components are given their finishing touch on a 3Dpolishing plant from Thibaut. In the picture, concrete balustrade elements for a mile-long promenade are just being given their finish

The software programme supplied by Progress was harmonised withTekla's software to form the centrepiece of this complex system

Wire preparation for mesh production is carried out with the well-proven MMR 16 straightening and cutting machine. The Progressrotary straightening technique assures that straightening qualityremains especially high and that the wires are processed carefully


www.progress-m.comProgress Maschinen & Automation AG - I-39042 Brixen (BZ) - Julius-Durst-Str.100 - Tel. +39 0472 979 100 - Fax +39 0472 979 200 - [email protected]

WE FORM YOUR WIRE

M-System – Tailor-made automation

Customised mesh welding plants for the cost-effective

manufacture of bespoke reinforcement mesh for a variety

of applications.

MESH WELDING PLANTS

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ment models generated with the Tekla soft-ware. Since almost every element manufac-tured at Hurks is a unique specimen, greatattention was paid to the system’s flexibility.Progress also proved to be the right partnerfor Hurks in implementing their wide-rang-ing concept including a fully automatedmesh welding machine, an additional plantfor bending meshes plus an automated sys-tem for distributing the reinforcing meshesto their appropriate stations.

Progress PTS – modern automation in mesh production Data from the models developed with theTekla software is stored in a database. Inthe production facility, this data is accessedautomatically and becomes the basis of fur-ther production stages. To take an example,an engineer draws up a plan for reinforce-

ment and the software makes the necessaryinformation available for the machines onthe mesh production line. Using this dataand the appropriate software from Pro -gress, the corresponding reinforcementmesh can be produced fully automaticallywithout any further intermediate stages inthe facility. The new Progress PTS software then checkswhether the individual reinforcements canbe produced by the machine as they weredrawn up. This software analyses the CADdata and informs the engineer working onthe Tekla model about its manufacturabilityfrom the machine’s perspective. If a meshcannot be produced, the programme dis-plays the problem areas so that they can beimmediately dealt with and resolved. PTSstands for “Production Test Service” and isa standard developed by Progress for sub-

mitting requests from CAD or master com-puter systems to a production system.

The ProFit software tool controls and organ-ises reinforcement production and conse-quently several machines. This facilitatesclearer management and control for theentire production department. ProFit adoptsreinforcement data from CAD systems. Themachine is then controlled by means of anetwork or barcode labels. The softwareprovides material retraceability for docu-mentary evidence relating to quality stan-dards. The bending shape encyclopaediacan be constantly enlarged.

M-System Evolution reinforcing mesh welding plantThe M-System mesh welding plant possess-es modern automation technology and

Like the entire plant, the welding gantry with the M-System meshplant is set up with an extremely great deal of flexibility so that meshes can be welded individually

The Progress mesh bending machine makes it possible to bend theentire mesh at all places desired. A particularly ingenious weldingtechnique ensures that crosswires in the mesh can be welded, if nee-ded, both from above and from below. This means that the mesh nolonger has to be turned before bending

The welded concrete reinforcing steel meshes are conducted to thebending plant by means of two robot crossbeams. The meshes aresubsequently positioned on prepared pallets and fed into the nextproduction process

In addition to the mesh bending machine, the Progress system alsopossesses single bending heads, which can bend wires within themesh. This function is very helpful for recesses such as doors andwindows and is counted amongst the system’s technological high-lights


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enables reinforcing meshes to be weldedeconomically in both transverse and longi-tudinal directions with a very great deal ofworkplace safety. Reinforcing meshes up to5 x 12 m, and with varying grids, dimen-sions and wire diameters, can be manufac-tured directly at Hurks on an individualbasis according to the input from the Teklamodels. The production runs fully automati-cally from a coil. Line and crosswires arefed into the welding plant fully automatical-ly. Any wire diameters from 6 mm up to 16mm available on the machine can be freelycombined with each other in both trans-verse and longitudinal directions and weld-ed with the Progress inverter spot weldingmachine.

A fully automated Progress MMR 16straightening and cutting machine is locat-ed at the beginning of the reinforcing meshproduction line. It straightens and cuts con-crete reinforcing steel in the required wirediameters, lengths and quantities directlyfrom a coil for line and crosswires. A rotarystraightening technique assures the continu-ous straightening accuracy necessary. Coilsfrom eight reels keep the MMR 16 suppliedvia the corresponding eight wire infeeds onthe machine.

Crosswires are conducted to the weldingmachine with a conveying system travellingunder the line reinforcing wire workingtables. One particular highlight with this

system is that the crosswires are not onlyable to be fed in and welded from under-neath, but from the top as well. This enablesmeshes to be produced with crosswireswelded on in differing ways. If a mesh isthen subsequently further processed in thebending plant, the wires will have beenwelded in such a way that bending cantake place fully automatically immediatelyafterwards – without any intervention onthe part of the machine operator.

The plant’s versatility provides the followingpossibilities for processing the meshes fur-ther: storage in a rack system with the aidof a turning crosshead, immediate ongoingtransport to the next production stage orinfeed into the plant’s centrepiece – themesh bending system.

Automated mesh bending Meshes in intermediate storage are hoistedfrom the rack with a special turning crane,which fixes them with magnets, turns them180° to set them down again on the auto-mated mesh bending machine’s workingtable. This bending plant is designed tobend both entire steel meshes as well as sin-gle wires from individual parts of the mesh-es, as is necessary for door and windowopenings.

The fully automated bending system carriesout any bending work necessary and formscages at any areas required. If needed, asecond mesh can be positioned onto analready bent mesh in order to form 3D rein-forcement for large-scale precast compo-nents.

Once ready, the reinforcing meshes are setdown on a formwork table and then con-veyed fully automatically to the individual

Magnetic crossbeams lift the completed steel meshes from the displacement carriage, turn them and reallocate them either to further processing or to stacking

The mesh displacement carriage is the central point of departure asregards further processing with the welded meshes. Since almostevery mesh at Hurks is a unique specimen, the flexible Progress system ensures that each mesh will be bent just-in-time and pro -cessed further after welding. The production stages have been optimised and precisely harmonised with one another

The robot-controlled positioning systems ensure that mesh logistics are efficient and reliable.All production stages run fully automatically in the Progress system. Only one person is needed to monitor the plant


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processing stations in an adjacent hall.Further formwork preparation and concret-ing take place there.

Processing the precast is not only carriedon in Veldhoven; a considerable amount isbrought to the production facility in Tilburgfor further processing.

Investment in new software and machine technology generates the desired competitive edge

With the changeover in the engineeringoffice to Tekla Structures, it became rapidlyapparent for Hurks that a very large stephad been made towards manufacturingwith a greater degree of automation andminimising error quotients. Nowadays, allprojects are modelled with Tekla; TeklaStruc tures is even utilised for preliminarycalculations. The Hurks Group had also dis-covered another reliable partner with thecommissioning of the first two Progressmachines in 2010. To fall back on productsfrom Progress when purchasing new meshwelding and bending machines was simplythe logical follow-on for Hurks.

Hurks obviously sees the future of Dutchcivil engineering as belonging to construc-tions with precast components. One of the

main challenges for Hurks is to preventerrors from happening in the first place,plus the ongoing optimisation of the entiremanufacturing process. With its partners,Tekla and Progress, Hurks is clearly con-vinced that it is on the right track towardsthese goals.

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FURTHER INFORMATION

Hurks prefabbeton bvLocht 1265500 AE Veldhoven, The NetherlandsT +31 88 1345000F +31 88 [email protected]

Progress Maschinen & Automation AGJulius-Durst-Straße 10039042 Brixen, ItalyTel. +39 0472 979100Fax +39 0472 [email protected]

Construsoft BVHengelder 166902 PA Zevenaar, The NetherlandsT +31 316 200000F +31 316 342454 [email protected]

Tekla Corporation HQ Metsänpojankuja 1 02130 Espoo, Finland T +358 30 66110F +358 30 6611500www.tekla.com

For Hurks Prefabbeton, the transport systemwas set up in such a way that each meshhoisted by the magnetic crossbeam can beimmediately positioned on a specially designed transport carriage


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