Elematic Acotec

Winner Application Renewed

New Acotec lines for high performance

After faithfully serving the operators for 28 years, the line for producing Acotec light partition wall panels has been renewed for even higher performance level and versatility. I have to say that I sincerely appreciate the skills of the designers of the original Acotec line for their fine work, which made it possible for the line to be competitive for such a long time. Of course continuous development took place during the past years, but finally the time came to take the technology to a new level and I can proudly say: New Acotec production line has been released!

Elematic Acotec

The first benefit we now can offer with the new lines is that you can select the technology level that which suits your needs as there are now SEMI, PRO and EDGE versions of the line available. So, with the SEMI you can start a factory with minimum investment while still getting good capacity and a high quality product. PRO has all the main functions automated, and the EDGE version offers a fully automatic production line with automated curing and packing.

When the investment decision is made, you usually do not want to wait for a long time for the production to start – you more or less want to see truckloads of panels shipped from the factory, unstopped like a river flowing. To make this come true as fast as possible, we took the modularity of the lines to a new level, so now a line module includes electrification and pneumatics. When also the line control was changed to state-of-the-art EtherBUS-system, the installation of the line is literally plug and work. This reduces the installation time to half what it used to be.

Acotec panel production

Acotec panel production

When you start the production, you don’t only want it to start quickly, but you also want it to run without interruptions. Nothing makes you go crazier than seeing alarms flashing, bells ringing and seeing the river of panels dry-up like a camel’s hump. This why we have made dozens of improvements to the new Acotec production lines: To make it run like a train. The conveyors are of new design and of new materials, and the new automation system enables faster movements of the plates and panels. The handling of plates is extremely gentle to maximize their lifetime and minimize dents, which would cause faults to panels and cause malfunctions in the line.

But it is inevitable that sometimes the train will stop. In such a situation you want to know why and where is the problem, to be able to solve it as fast as possible. That’s just what the new Acotec line does. On its control screen, it shows the location of the fault on a map (layout of the line) and tells in plain language what the problem is, also giving advice on how to fix it. This way the line is back in operation in a blink of an eye. Furthermore, mistakes in solving the malfunctions, which could damage the machinery, are prevented.

So, when in no time you have your own river of panels flowing again like the river Amazon, you can relax and check the latest automatically generated production reports from the control system. Seeing that the planned capacity is reached and downtime and level of rejected slabs lower than the target makes, you do not need to worry. You can just concentrate on enjoying doing business with Acotec from Elematic.

Jani Eilola, Product Line Manager, Floor Technologies and Acotec

Smart precast production needs up-to-date automation

Elematic Automation Upgrades

Every factory, technology and machine has its optimal lifetime. Same applies on factory automation. The lifetime can be extended with regular maintenance, but eventually newer choices just perform better.

Up-to-date production technologies shorten precaster’s reaction times and ensure premium end-product quality, as I wrote in my post earlier. What is often overlooked is the renewal of production automation. In this era of technology-driven competitiveness, smart integrated renewal of all production components is a key.

Shorter and less damaging production downtime

The repair of existing automation hardware might be impossible, if the original automation solution dates back for several years. The hardware is just out-of-date, and there are not any spare parts available anymore. Then the whole production automation components need to be re-designed and rebuild. Production downtime is easily couple of weeks instead of couple of days or hours, which certainly affects your profitability. Also in automation preventive maintenance is the key. By updating hardware on time, even if it does not show any problems, you will save yourself from headache!

3 tips for smart upgrades

  • When have you last time upgraded your Extruder EL900E nozzle module  or levelling beam assembly? 
  • Did you know, that there is more advanced automation technologies used in E9 series Extruder?
  • Hardware and software related to your concrete transportation and batching and mixing plant management are also worth checking, since they are crucial for good production flow.

 Petteri Laitinen, Director, Customer Services, Elematic

Perfect match of precast and affordable housing in India

There is huge housing demand all over India. Already over 30% of India’s population, that is over 377 million people, lives in urban areas. The urban housing shortage has been estimated to be 25 Million residential units at the start of the 12th five year plan in the year 2012.

Four storey walk-up apartments made of precast

Four storey walk-up apartments made of precast

Residential buildings have the highest market potential, specifically in the LIG (Low Income Group) and EWS (Economically weaker section) housing sector. According to data available with Brick Eagle, a financial services firm for affordable housing in India, the demand for affordable housing in India is around 18.8 million square meters. The size of these units is in the range of 30-50sqmt.

Affordable housing made of precast in India

Affordable housing schemes of the Delhi Development Authority, DDA. 18,000 houses in 3 years delivered. Another project of 27,000 houses in next 3 years.

Now, affordable housing schemes of the Delhi Development Authority (DDA) have approved precast technology for all their future projects and plan to construct 100,000 units every year.

Speedy, sustainable and versatile precast as a solution

Huge demand like this requires new type of building construction solutions. Precast is an optimal choice for those valuing short construction times and reduced lifecycle costs of buildings. That is why high quality, maintenance free precast walls and floors have been approved as the main building material for several major residential, commercial and public building projects in India.

For High Income Group (HIG), Amrapali Group is constructing G+22 and G+33 story buildings in Greater Noida and will develop two major group housing projects in the next four years totaling 35mn sqft. Precast suits well for villas, too. Janapriya Syndicate has constructed both 2B+10 story buildings and many villas in Sainikpuri, Hyderabad.

Precast, architechture, commercial buildings, Elematic

Precast column-beam frame with hollow-core slab for commercial mall. Large spans of 10-12 m for column free spaces and  better architectural flexibility.

Commercial mall, precast, India, Elematic

Completed commercial mall made of precast.

VME precast of Chennai have completed many commercial projects, e.g. malls, offices, shops, in and around Chennai along with supplying precast elements for external projects.

Hospitals, precast, Elematic

500 bed multi speciality hospital using precast columns, beams, hollow core slabs and façade panels.

In South India, the KEF Company, is constructing a 500 bed hospital and many schools as part of the philanthropic interests of the company’s founder and chairman using precast concrete technology.

Profitability by professional precast building concept planning

The biggest bottleneck in the implementation of precast technology in India is a lack of experienced professionals (architects, structural designers etc.) who have worked in precast concrete building construction.

However, with the increase in the use of modern construction techniques, there are many consultants now in India providing these specialized services. Elematic also provides end-to-end structural design services with a dedicated design team based in Pune, Maharastra.

Chander Dutta, Managing Director, Elematic India

Precast in building foundations

Industrial Pile Driving, Elematic, Foundations

Industrial Pile Driving is the greenest way to pile with an unforeseen productivity

We want to understand and find the most suitable solution for customers’ need every time. This sentence in our values describes well the starting point we had in our offering development in the end of last year.

Precast has established itself as a modern way to produce floors and walls for any type of a building. But could it be more? Could the same benefits of high quality, excellent productivity, safety and profitability be achieved in underground building construction?

Precast foundations, Elematic

Precast products for sustainable building foundations

Yes, yes and yes. Industrial piling solution shows the way. The solution combines
• An easy add-on to your current production without any new raw materials
• The lowest labor requirements
• A flexible production
• The best overall control of the production process
• The greenest way to pile with minimized ecological footprint
• An unforeseen production of even 3 km of ready-to-install piles per day!

Precast concrete piles, Elematic, Pile Caster

Pile Caster for efficient precast concrete pile production

To put it in short, for a precaster, precast concrete pile line offers new business opportunities and better market value easy and uncomplicatedly.

Ismo Kallio, product manager, Elematic

Beautiful and safe precast in Russia – with Love!

#precast #buildings

Atmosfera housing project by YIT in Russia

Russia has been a central part of my life for the 21 years. My first experiences with this great country date back to 1990´s when I moved to St. Petersburg to work there. Since then many things have changed, but also many things have remained the same.

Building construction in Russia 

In the early 90´s St. Petersburg was a typical ex-Soviet city where the economic growth was taking first steps. Many western companies started investments and opened subsidiaries in Russia. People began to move in to big cities searching for jobs and a better standard of living. And it is still going on.

The need of new flats is huge in all major Russian cities:  in Moscow they are building 4,5 million SQMs/year and in the Moscow about 5,5 million SQMs/year. In St. Petersburg and other big cities the annual volume of built housing is from 1 to 3 million SQMs.  In 2010 there were 714 000 completed homes in Russia.

Precast concrete building traditions

#precast, #precasttech

New precast factory of YIT in Russia

It is clear, that such huge building volumes put a great challenge to constructors to find the most cost effective way of building. Russia has a long history with precast concrete buildings. The value of this ready-to-install building product has been recognized widely. Old problems related to the quality of precast products and buildings can be easily solved with modern building methods and precast manufacturing technologies.

Effective building construction

#precast #piles

Precast concrete piles for safe and sustainable foundations

The typical size of supplied precast factories can vary from 100.000sqm- 500.000 sqms of housing per year. Less manpower is needed thanks to more and more automated processes and advanced technologies. Using prefabricated concrete products allows the constructors to maintain the high quality of houses even when building during the wintertime. The modern precast connections can be made safely in temperatures even up to -20 degrees Celsius.

Modern solution for sustainable foundations

#Precasttech for #Piles

Precast concrete pile production line

Many big Russian cities are located on river banks and see coasts. In such conditions houses must be built on pile foundations. Elematic has developed a unique production plant for foundations: it is possible to produce even 3 KMs of piles/day on a single plant. This is not possible using other solutions on the market. In St. Petersburg we have a client, who has recently bought a 3rd such line. This is just one example of the great market opportunity waiting for modern precasters.

 Harri Lahtivesi, Elematic’s area director for Russia

 

Early birds of 3D – never stop chasing your dream!

I joined precast business in the early 80’s. Since then basics of the business have not changed too much but the usage of precast is widening every year. People are after fast, practical and private housing solutions. These have been the precast advantages from the day one.

Precast building construction

Precast business is not stagnated though. I would describe it to be a field of small incremental change. There have been several radical innovations in the pipeline during the years, such as 3D facades developed in the project Dimenssio in the early 90’s. The timing and competencies were just not right then.  Nowadays, when 3D printing technology has taken giant leaps to become an everyday reality, I’m just thinking that should we dig into this idea again?

Industrial and affordable building solution for fast urbanization

Precast has also always been an option when deciding on the building construction method. This applies on not only housing projects, but also on industrial and commercial building. Nordic countries have been in the front row of this building method development during the years.

In today’s world precast projects are started more and more in the areas with no precast building traditions. Social pressure to find industrial and affordable building solutions achievable for large populations is high.

More precast knowledge across the whole value network

Within these new markets, the knowledge and know-how of safety and sustainability in precast should be supported actively. Development needs to be done in the building construction value networks – with architects, structural designers, builders and manufacturers.

The importance of the right and up-to-date knowledge is underlined even more now, when Internet has the strong role in the solution and supplier search. Internet is a perfect channel to get familiar with the global offering. But the offered options need support and validation by real and local references and adaptable technological solutions lasting time. One example of the required knowledge could be precast solutions’ material efficiency.

Elematic EDGE floor production plant

The EDGE floor production plant with 8 beds for a reference

With these thoughts and experiences, it is my delight to continue my precast career more as an advisor and hunt my dream of a state-of-the-art 30-line hollow-core slab factory!

 Eero Virtanen, Commercial Director, Elematic

Can precast be inspirational and beautiful?

Precast housing reference

Apartment building with a graphic concrete facade in Espoo, Finland. Construction year: 2013.

This question we are often asked. Our answer is definitely yes! I’m glad to notice that this thought is more and more widely accepted and also applied around the world.

Since the late 1990s Graphic Concrete  has been working with projects ranging from industrial buildings to schools, hospitals and commercial and residential buildings.

Industrial precast building

H.A.N.S., Industrial Precast Building, Czech Republic. Construction year: 2009.

Our core idea is to create premium precast concrete surfaces and that way inspire people in their everyday environments. Preferences vary from a region to region. When Southern European and Arabian consumers prefer strong and clear ornaments on their building surfaces, Northern Europeans are more into non-figurative patterns and textures. One of the top surfaces has lately been nature in its various representations.

Graphic concrete

Example of an ornament as a graphic concrete surface figure.

We call these surfaces graphic concrete – according to our patented technology. We offer a real industrial and cost efficient product for large-scale surfaces, which can also be visually creative.

Precast slabs

Sample slabs with graphic concrete surfaces

Today the technology is a proven concept within the prefabrication concrete industry. Versatile buildings demonstrate the vast range of graphic concrete applications in e.g. facades, walls and pavement slabs. All these are possible without compromising the uniqueness of a building and the vision of an architect.

Industrial precast building

Industrial precast building: KV Tändtickan, Göteborg, Sweden. Construction year: 2013.

One important point is, that graphic concrete is not an additional cost. Every precast concrete facade or wall has always a surface. So it is more a choice between inspirational and monotonic surface than anything else.

Harri Lanning, Managing Director, Graphic Concrete Ltd

Homes for people – with a window in a bathroom

Image

India is an overwhelming experience. Even after my several visits there, this feeling does not fade away. For a Finn coming from a country of 5 million people, truly understanding the scale of Indian city development makes you almost freeze.

Many aspects of building construction being self-evident for us are not that in India. Use of water and work force for instance. Lack of both of them forces India to develope their building methods.

Not to mention a billion people in search of a new apartment or house within next 20-30 years from here!

Based on my 2-year Elematic experience, I would vote for the precast as a perfect fit for India.  Actually, I could even say, that precast is the only building method fast, flexible and affordable enough for the needs of India.

Mats Jungar, Managing Director, Elematic Group

Competitiveness in precast production lifecycle, part 3

During last years, competitiveness has been one of the main issues in our customer discussions. In precast concrete factories, staying competitive is a multi-dimensional effort concerning not only production lines and machinery, but also operator skills and operational best practices.

In precast concrete factories, competitiveness concerns not only production lines and machinery, but also operator skills and operational best practices.

In precast concrete factories, competitiveness concerns not only production lines and machinery, but also operator skills and operational best practices.

In this blogging, I share my views on how a precaster and a technology supplier can cooperate to improve the competitiveness of a precast investment. This blogging also continues the blogging series on precast production lifecycle started by Petri Vesa.

Operational competitiveness of a precast factory

I prefer to have people thinking over machines. Even so I work in a leading precast technology company. No factory can operate optimally, if people – operators, production managers, designers, owners – do not develop it.

Profitability of a factory requires parallel support for hardware, software and people. One way to acquire all of these is our Precast Academy, the only training concept of its kind available in the market.

Elematic provides you with factory lifetime support  to increase profitability of your investment

Elematic provides you with factory lifetime services to increase profitability of your investment

As its best, a technology supplier can offer for a precaster similar references and industry knowledge on operational best practices based on proven track record.

Local factory service and maintenance

In major capital goods investments, daily productivity is in the core of the investment profitability. When a machine breaks, fast delivery of the right spare part is essential. Preventive maintenance contract with regular machinery inspections and factory visits is a minor cost, but a major element in the creation of competitive advantage.

Ways to ensure the daily productivity of your precast factory

Ways to ensure the daily productivity of your precast factory

Production renewals for competitiveness

Finland was ranked as the world’s third competitive country by World Economic Forum Competitiveness Report 2012-2013 .

Strong part of Finland’s competitiveness is mechanical engineering; companies in this sector know how to apply new technologies rapidly to customer-driven products and production processes.

In building construction sector, Finland has gathered unique cluster knowhow in precast building design, connections and production. Also, our building construction companies are internationally recognized of their quality work.

How does this then benefit a precaster?

Technology innovation and engineering tradition is a firm base for continuous development. For a precaster, benefits come in the form of

–       faster reaction to market needs,

–       more cost-effective manufacturing models and processes, and

–       premium quality machinery.

 

Inspections and factory audits to stay competitive

Inspections and factory audits to stay competitive

 

It would be interesting to hear your experiences in your precast investment development. And by that continue the discussion on how we could make the precast industry even more competitive together.

Meanwhile, Happy Holidays!

Petteri Laitinen,  Director, Customer Services, Elematic

From a plan to an efficient precast factory – precast production lifecycle, part 2

Elematic choses as the one-stop-supplier for Bismayah

The brand new precast city of 500,000 inhabitants and 100,000 apartments will be built in Iraq in 7 years

After inspiring and hectic Bauma 2013 with 530,000 visitors from over 200 countries I feel confident to share with you some tips for trouble-free precast factory delivery. This blogging continues the views on profitable precast production lifecycle presented in the part 1.

Optimizing the production flows

A good precast production technology and investment planning is characterized by close cooperation of various building construction stakeholders. When entering a factory building phase, more direct communication between a precaster and a machinery supplier more efficient precast factory.

Elematic and precast production design

Precast factory building planning hand in hand with production design improves factory’s efficiency

A precast factory building can be used many ways as a space. To optimize the efficiency of the factory, effective layout of different processes is a key. The layout of processes in the factory should not only minimize the movement of employees and production equipment, but also the logistics at the production site.

Elematic provides concrete transportation plans for the site

Original technologies turn into original machines manufactured by Elematic

Another critical production efficiency issue is concrete transportation and distribution at the site – to make it as smooth as possible both inside and outside the factory. Also, different geographical locations may require different concrete production solutions resulting varying transportation needs.

Elematic and factory set-up

Supervision and consultation are available to ensure factory’s optimal operation

In a machinery start-up, installation supervision and raw material and concrete mix consultation are provided to ensure factory’s optimal operation. The overall timeframe of the factory set-up can vary between 0.5-1 year.

By the way, do you know Bismayah already?

Elematic and Bismayah

Elematic was chosen as the one-stop-supplier for the world’s largest precast concrete factory

A good way to follow precast factory delivery almost in real-time is via Bismayah project. It is the biggest precast concrete project in the world so far. The brand new precast city of 500,000 inhabitants and 100,000 apartments will be built in Iraq in 7 years. Bismayah starts in full speed just now. Elematic is chosen to a one-stop-supplier for a precast concrete factory that will be the world’s largest of its kind.

Petri Vesa, Sales Director, Elematic