Ready for installation. That is the concept behind Spaansen that lives up to its name: completely finished façades that are produced under controlled conditions and guarantee high reliability and a long service life. Production uses a carousel system that Hendriks precon developed in close collaboration with Spaansen and the robot supplier. "A fine example of collaboration that we are very pleased with," says Spaansen director Ab Knook.
Gevelklaar is the result of a rich history in prefabricated façade construction. A history that began with prefabricated concrete shell elements. "A few years ago, we made a conscious decision to deliver more added value," says Ab Knook. "The solution was found in façade elements based on the existing concrete shell, including provisions for electrical and water pipes. These elements were enhanced with window frames, insulation and ceramic brick strips."
A completely new factory was developed for the production of these Gevelklaar elements. Hendriks precon was quickly chosen to automate the production process. "In 2016, we did a project with Hendriks precon to increase our production, and not long after that, they were also involved in the expansion of a production hall," says Ab Krook. "The choice was therefore easy. Together with Hendriks precon and the suppliers of the robots and equipment for processing the insulation boards, we formed a team that took care of the complete automation of the production process. Smart engineering and tight coordination ensured that everything was delivered on time and according to our wishes. A real work of art!"
Anyone stepping into the production hall will quickly realise that this statement is no exaggeration. The production process looks like a tightly organised and smoothly running machine. The concrete elements that enter the Gevelklaar factory on A-frames are placed on a tilting frame from Hendriks precon using an overhead crane. The frame has space for two large façade elements, which are tilted into a horizontal position. Then a sophisticated process of movement in longitudinal, transverse and vertical directions begins. The elements are transported in longitudinal and transverse directions via an electrically driven longitudinal guide. "The trick lies in the high demands we place on movement in the x, y and z directions," says Ab Krook. "We achieved this with an accuracy of ±1 mm!"
The highlight of precision and speed is clearly visible at the point where the robots come into view. The insulation boards are then automatically provided with adhesive grooves. In the next production phase, the facade elements are provided with facing bricks by robot arms. To do this, the table with the facade element is hydraulically lifted and secured with clamping blocks. What makes this so interesting is the high speed at which the 25-tonne element is then moved again to make the best possible use of the robots' capacity. The robot has a reach of 60 cm; once the facing bricks have been glued, the table with the facade element must be moved as quickly as possible. In total, the movement takes no more than 6 seconds, including the hydraulic lifting and lowering of the façade elements.
In order to meet the required tolerance of 1 mm, the longitudinal guide drive is equipped with a servo motor and frequency converter to quickly increase and gradually reduce the speed, but also to guarantee the exact location of the table to be transported. The associated control system and smart touchscreen operation were also supplied by Hendriks precon. In addition, Hendriks precon engineered and supplied all safety features around the carousel. Examples include practical safety gates and light screens, platforms and machine safety, as well as advice based on risk analyses and working with safety zones.
Ab Knook is rightly proud of the result: "We are currently the only company in the Netherlands doing this. Our elements have a high insulation value and ensure a very clean construction site. You can safely say that their use has a huge impact on sustainability. It's great to see that we have achieved this with suppliers such as Hendriks Precon. They are a great company to work with and a masterpiece of engineering and technology."
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