For your precast concrete production you want a partner who can offer you

customized plant concepts and state-of-the-art machine technology.

made in Germany

Precast Success

1925

1960

1978

2012| 32 |

Vollert is an internationally acknowledged expert in precast concrete production and leading partner for building materials manufacturers, building companies and building contractors. We have a passion for designing intelligently conceived plant engineering and machine concepts that are optimally customized to meet our customers’ requirements. It is this passion which drives us ahead, day-by-day.

With this in mind, we advise our customers on the latest precast construction technology in the area of residential and industrial building, and develop turnkey plant solutions. From straightforward start-up concepts through to highly automated multifunctional systems, we should be the first point of contact for your next project, as

• we have experience from over 300 precast concrete plants worldwide.

• we continuously develop our machine technology to make the precast concrete plants of tomorrow even better, more economical and safer.

• we have a highly trained team of civil and mechanical engineers as well as project managers who are very committed to working to develop the best solution for you – with an international presence and at your service anywhere.

We provide the expertise, engineering knowledge and technology that keep you at the forefront of your market. This is what we call ‘Precast Success’.

Yours

Expertise, innovative power and experience

made in GermanyTradition, innovation and global presence – since 1925.

1925: Foundation of the company by Hermann Vollert, the grand father of the current generation of managers

1954: Expansion of rail transport systems for brick works and company´s rise to become market leader in conveying systems in the fine ceramics industry

1962: Delivery of the first concrete bucket conveyor

1971: Commissioning of the first pallet circulation system for a precast concrete plant in Germany

1996: Development and patenting of the first compaction system with innovative pendulum technology

2003: With its partners, Vollert delivers and installs the largest precast concrete plant in the world in Bangkok

2011: Establishment of the first subsidiary, Vollert India, based in New Delhi; further subsidiaries follow in Brazil, China and Russia

2012: Vollert as a pioneer: the first automated circulation systems for the production of precast concrete parts start operations in Singapore and India

2012: Acquisition of formwork specialists Nuspl and enhancement of the portfolio with stationary specialized moulds

As one of the technological leaders, we offer solutions for the production of plane and structural precast concrete parts. High performance tilting tables and battery moulds for stationary production, automated circulation systems for the production of walls and slabs or special moulds for beams, columns and precast stairs – whatever your requirements, we will provide the best concept for your project.

The precast concrete plant of tomorrow aspires to the latest machine technology, with optimized workflows and new production methods. Innovations ensure more rational operations, lower material and labour requirements as well as higher-quality precast elements.

From the first draft to a turnkey, forward-looking plant concept, we are the partner you can rely on. We address each customer requirement individu-ally and provide customized solutions. This is what makes our solutions successful on a long-term basis.

We know what makes precast concrete plants successful.

made in Germany

Precast SuccessInnovative plant engineering concepts "made in Germany",

offering the necessary investment security for your project.

Reaching out from Weinsberg right across the world:

Vollert systems are based in Baden-Württemberg, in

the south of Germany. An area known worldwide

for its inventions and creative genious.

Alexander KasparHans-Jörg VollertBjörn Brandt

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Plant solutions for plane semi-finished precast concrete partsMarket demand for semi-precast systems, such as floor slabs and double walls is increasing in more and more countries.

Plant solutions for plane solid concrete parts For many years, plane solid concrete parts, with or without insulation, have been the classic precast concrete elements in use in residential and industrial buildings worldwide.

Double wall with insulated core Core-insulated double walls have internal insulation between the concrete slabs. This combination offers a completely new range of applications and almost always guarantees compli-ance with heat insulation regulations for buildings.

Façade element Façade elements are industrially manufactured solid walls

characterized by a wide variety of surface designs. The spectrum is enormous and ranges from traditional ex-

posed aggregate concrete to brick structures and matrix structures through to marble surfaces. The reinforcement

necessary for static rigidity is also included.

Floor slab The floor slab is a reinforced concrete slab with a thickness of 5 – 7 cm, depending on the concrete covering and rein-forcement content. The torsionally stiff reinforcement to give stiffness once installed as well as the flexural tension reinforcement lengthways and crossways, are generally pre-installed. With the addition of in-situ concrete, the floor slab becomes a solid and monolithic reinforced concrete floor.

Solid wall/solid slabs Solid walls and slabs consist of 10 – 50 cm-thick solid

concrete elements made of standard or lightweight concrete incorporating static reinforcement, and are frequently used

for interior walls of cellars and for ground floor and upper storey walls (load-bearing/non load-bearing). In-situ concrete is not required; large-format concrete elements mean rapid

construction is guaranteed.

Double wall The double wall is made of of concrete slabs, with a thick-ness of 5 – 7 cm, each held together with truss-type rein-forcements. After installation, the remaining void is filled with in-situ concrete – resulting in a monolithic, dense and extremely solid concrete element.

Sandwich wall Sandwich walls are characterized by an insulating layer

which is enclosed by concrete on both sides. On one side is the load-bearing layer, with the required static reinforcement;

on the other side the visible layer, which is frequently made of coloured concrete or may have different surface textures.

HQ Legal & General Group, London Architects: Architects David Walker, London

Source: decomo

Office & Business Park in Munich (former AGFA estate)

Architects: Architects Hild und K, München

Source: decomo

Ministry of the Interior, Kingdom Relations/ Ministry of Security & Justice, The Hague

Architects: Prof. Hans Kollhoff Architects, Rotterdam

Source: decomo

Precast construction setting worldwide trends

in residential and industrial buildingsPrecast construction is setting new trends in residential and industrial buildings worldwide and shows what is architecturally possible nowadays. From one-family homes to multi-storey apartment buildings, through to multifunctional industrial buildings and high-quality, sophisticated façades – the sky is the limit. Moreover, precast constructions are considerably less expensive and, above all, faster to build than conventional construction technology.

As your expert partners, Vollert and Nuspl provide broad engineering expertise with regards to current technologies for plane and structuralprecast concrete parts and the most cost-effective production processes.

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Automated circulation systems for maximum plant productivity

From conception to the turnkey plant solution –

with Vollert you rely on investment securityStationary plant solutions made by Nuspl

Battery mould Loading beamHigh performance tilting table Curing chamber/storage retrieval machine

Beam mould Turning device for double wall production

SMART SET shuttering robot

Today, automated circulation systems from Vollert set the technical standard worldwide in the field of modern precast production. Pallet circulation systems with Vollert technology provide cost-effective production processes combined with an optimum degree of automation. State-of-the-art machine technology ensures rational work processes – from CADCAM-controlled shuttering robots, fully automated concrete spreaders, innovative turning devices for double wall production, through to intelligent loading and lifting technology.

We develop a plant concept customized to your requirements – from the first 3D simulation and calculation models through to the plant configuration with state-of-the-art machine technology. This is because the best solutionis always customized, and depends on the produced precast concrete parts, the level of automation, the amount of investment and the required levelof system flexibility. At the same time, we offer you maximum customer benefit, from straightforward stationary solutions through to highly automated circulation systems.

Battery moulds and high performance tilting tables from Nuspl for the stationary production of solid, sandwich and façade elements have proven themselves in the market over many years. Solutions for the production of structural concrete elements such as column and beam moulds, as well as stair moulds and special moulds, for lift and light

shafts for instance, complete the wide range of products and services that we offer with the long-established brand.

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State-of-the-art formwork from Nuspl for each requirement

Column and beam moulds

Multifunctional moulds for columns and beams, pre-stressed or reinforced – in hydraulic or mechanical configuration, as a mono or duplex mould. The lengths can be freely selected and the production heights and widths can be adjusted to almost all applications.

Battery moulds

High performance battery moulds for the vertical production of single layer, large area walls and slabs. A relatively large mould surface is available on a comparatively small base surface. The initial shuttering work is minimal and the use of space is maximized.

Stair moulds

Technology for state-of-the-art stair production in exposed concrete quality – whether vertical or horizontal, overhead or for extra wide stairs. The tread is continuously adjustable from 220 – 350 mm, the rise from 150 – 220 mm, with stair widths from 900 – 1,500 mm.

Special moulds

Special moulds for all uses: for light and lift shafts, towers or special parts, for example.

Tilting tables

High performance tilting tables for the flexible, horizontal production of plane wall/façade elements and special parts. Production widths of up to 5 m and lengths of up to 100 m are possible with a surface load

of up to 1,000 kg/m2, configured individually or as tandem solution.

Concrete plant equipment

A wide range of accessories and equipment for modern precast concrete plants – from shuttering pallets, concrete spreading systems

and loading traverses through to transport vehicles and racks.

"You want a partner that offers various

production methods for the best solution.“

Alexander Kaspar

With the long-established Nuspl brand, we offer stationary solutions for plane precast concrete parts and multifunctional moulds for structural concrete elements in both pre-stressed and reinforced configurations.

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Machine technology from Vollert

for automated circulation systems Concrete spreaders and compaction systems

Concrete spreaders ensure the precise application of the concrete – crane operated, as a bridge or portal concrete spreader, with a do-sing screw, gate valve or belt out-feed, fully or partially automated. Modern compaction stations with patented Vollert technology for a superb surface and edge quality.

Preparation operations

Ultra-modern pallet and shuttering cleaners, CADCAM-controlled large plotters and lasers for optimum work processes in thepreparation of concreting work.

Curing chamber and storage retrieval machines

Fully/partially insulated rack systems for the curing of freshly concreted precast parts. Ultra-modern storage and retrieval equipment ensures fully automated storage and retrieval of pallets from the curing chamber.

SMART SET shuttering robot

SMART SET shuttering robots ensure the highest efficiency in the plotting and positioning of shuttering profiles and insert parts. Maximum precision is combined with the highest performance

values at speed and acceleration.

Surface finishing technology

The latest surface finishing technology for exposed concrete quality: using smoothing machines and rollers, extractors and washing and

blasting stations.

As a pioneer in circulation technology, Vollert offers expertise from over 300 automated precast concrete plants and the most up-date machine technology on the market.

"You are looking for a partner for your

precast concrete production who offers

the best cost-benefit analysis.“

Philippe Marrié

Turning devices for double wall production

Floor-bound and overhead pallet and vacuum turning devices. Synchronous compaction, without associated movement, prevents

the separation of the concrete in the reinforcement area.

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Intelligent control technology and cost-effective production processes

Shuttle systems

Shuttle and transfer cars for the delivery of loaded transport racks to

external areas for loading.

Circulation technology

State-of-the-art circulation technology for efficient production processes and maximum plant productivity. Intelligent transport and conveying technology, combined with innovations such as overtaking systems avoid downtime or waiting times.

Lifting traverses/ loading traverses

Traverses for the safe loading of precast concrete parts for

transport to the building site.

Control and management systems

Order management, storage and retrieval processes, the process machines as well as pallet transport in the production line are all controlled and visualised. Analyses give a clear indication of the

circulation system’s cost-effectiveness and production rates.

Tilting stations for loading processes/ lifting platforms

Hydraulic tilting stations for the vertical stripping of pre-de-moulded wall elements.

Lifting platforms ensure safe loading processes.

Today, sophisticated circulation technology, combined with intelligent control engineering systems, are key factors in modern precast concrete plants. Their configuration requires a high level of expertise interms of workflows and the different production methods.

"In each country the construction technology

is different. You want a partner for your

precast concrete production that knows

about that.“

Igor Chukov

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Machine and plant technology for state-of-the-art concrete sleeper productionNowadays, railways and railway networks are equipped with concrete sleepers. To respond to the demand from private industry and the public sector, manufacturers of precast concrete parts and building companies are making ever-greater investments in highly automated production systems.

We have been automating concrete sleeper production plants for over 30 years, becoming a trusted industrial partner in the sector. For pre-stressed concrete sleepers and low-vibration tracks, we offer complete mould circulation systems for many different production methods and sleeper types – for mono-block sleepers, bi-block sleepers, late demoulding processes or immediate demoulding processes. From upgradeable start-up concepts, with low levels of automation, to the largest concrete sleeper plants in the world, Vollert is active all around the globe.

"You want a partner for your concrete

sleeper production that supplies you

customized technologies.“

Steffen Schmitt

• Plant solutions for sleepers using the immediate demoulding process or late demoulding process

• Plant solutions for different types of sleepers and fixing systems

• Circulation systems and stationary production lanes

• General retrofitting, plant relocation, servicing and maintenance

The pre-stressing process is initia-ted to destress the tension spindles and transfer the wire pretension to the con-crete. The sleepers are knocked out of the mould by a turning device, with subse-quent, quality-controlled final assembly of the rail fitting.

Mould manipulator for fully automa-tic handling of the sleeper moulds in and out of the stock areas in the temperature-controlled curing chambers.

Concrete spreader with worm-type material discharge to provide uniform, semi-automated filling of the concrete sleeper. In addition, the mould will besimultaneously vibrated for concrete compaction.

Concrete preparation: Oiling, cleaning, positioning of inserts and reinforcement, pre-tension of wires.

Vollert Anlagenbau GmbH

Stadtseestrasse 12

74189 Weinsberg | Germany

P: +49 7134 52 0

F: +49 7134 52 203

precast@vollert.de

www.vollert.de EN/0

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Vollert do Brasil Ltda Belo Horizonte | Brazil

Vollert Commercial (Beijing) Limited Beijing | China

Vollert Anlagenbau GmbH Weinsberg | Germany

Vollert India Pvt Ltd New Delhi | India

Vollert RU OOO Moscow | Russia

Nuspl Schalungsbau GmbH + Co. KG Karlsruhe | Germany