CONCRETE PRODUCTS & CAST STONE Masa GmbH, 56626 Andernach, Germany

Turnkey concrete block plant from a single source Masa GmbH has been a reliable partner to the building materials industry for 110 years. With many years of experience in the manufacture of facilities for production of high quality paving, curb and block stones, Masa was also able to impress the Rewa Beton firm in St. Vith, Belgium. In this project, Masa not only delivered the complete machine technology, from mixers to the packager, but also put a complete package in place as general contractor for the customer that also included the new production hall. The Rewa firm was only responsible for the concrete work (floor slab, bunkers for aggregates, etc.). Everything else was supplied and assembled by Masa or subcontractors at Masa’s responsibility. Masa implemented the turnkey project to the customer’s complete satisfaction. Mark Küppers, CPI worldwide, Germany The Rewa firm was established in 1983 and taken over in 1995 by Portlandzementwerk Wotan H. Schneider KG from Üxheim in Germany and the BODARWE CARRIERES sa road building firm from Belgium. Rewa previously manufactured on one production line and was able to more than double its capacity with the latest investment in the Masa plant. The Rewa plant in St. Vith sits in a rural region at the border triangle between Belgium, Germany and Luxembourg.

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With a broad-based product range, the company has made a name for itself across borders and been able to assert itself in the market. The most important markets, each with approx. 40%, are Luxembourg and Belgium. The remaining 20% is delivered to Germany. The delivery radius is normally limited to approx. 50 km. The hollow blocks and road construction products produced by Rewa are not building centre goods, but mainly go to the building materials trade. With the new con-

crete block line from Masa, the company was soon able to open up additional markets. The new production facility is equipped with a dosing system for coloured concrete that enables custom colour choices for paving stones or other concrete goods. Thus, in addition to the manufacture of kerb and edging stones, concrete paving stones are also produced. For Rewa a precondition for awarding the contract to build a new concrete block production line was that the contractor offers a

The new Rewa concrete plant in St. Vith, Belgium

The two silo facilities for aggregates (left: core concrete, right: facing concrete)

The five aggregate silos for the facing concrete mixer

The aggregates from the silos are measured onto a conveyor belt that places it in the lifting bucket.

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www.masa-group.com Masa covers the complete range of machinery and ancillary equipment for the building materials industry: Batching and Mixing, Concrete Blocks/Pavers, Kerbstones, Concrete Slabs, Sand Lime Bricks and Aerated Concrete (AAC) Products. All technical solutions are individually planned, designed, adapted and realised for each customer, resulting in one supplier and one individual contact person.

Masa GmbH Masa-Str. 2 56626 Andernach Germany Phone +49 2632 9292 0 Service Hotline +49 2632 9292 88

Masa GmbH Werk Porta Westfalica Osterkamp 2 32457 Porta Westfalica Germany Phone +49 5731 680 0

[email protected] [email protected] www.masa-group.com

Masa - made in Germany.

CONCRETE PRODUCTS & CAST STONE turnkey package, including the new production hall. This task was a new challenge for Masa. But the machine and plant engineers were able to impress with the result. “The overall package from Masa was just right. We cover a broad production palette with the new facility”, says the CEO of Rewa Beton, Werner Jousten. “We had many special requests, which were all implemented”, he continues. “Almost every problem could be solved, thanks to excellent coordination by Stefan Knühmann (Masa project management director). Masa’s debut as general contractor can only be described as successful.”

“From the beginning, the quality of the stones produced on the Masa plant was better than the products that we made on the old plant. The density is higher and the height tolerances are good”, says Jousten, summarising the successful commissioning. Meanwhile, the plant is in regular operation and the Rewa product range has been significantly expanded. “This gratifying development was also undoubtedly based on competent training of our employees by Masa. The excellent remote maintenance by Masa is a further factor”, says Jousten, speaking of the excellent collaboration between the two companies.

The new production line has been running since the end of March and also produces stock goods, for which there is ample storage space available on Rewa’s very expansive outdoor area. Six additional employees were engaged for the new Masa production line, so there are now 15 people working on concrete goods production in St. Vith.

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The elevator is equipped with soft start and brings the aggregates to the upper mixer level.

PH3000/4500 core concrete mixer (rear) and S350/500 facing concrete mixer

The mixers empty onto conveyor belts that transport the concrete to the block making machine

Colour-Mix-System with 3 silos and mobile dosing belts

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Masa XL 9.1 concrete block making machine

High-performance concrete block production with the XL 9.1 concrete block making machine Masa GmbH from Andernach has extensive know-how in the production of high quality concrete blocks from light or heavy weight concrete. The appropriate concrete quality to meet the specific requirements of block production is prepared in the Masa dosing and mixing machines. Eight aggregate silos were installed in St. Vith for the core concrete mixer and five aggregate silos for the facing concrete mixer. Five cement silos ensure an adequate stock of raw material, even under full utilisation of production. 4-colour dosing with liquid colours (core concrete 2 x 60 l, facing concrete 2 x 20 l) was installed in the concrete production facility for colouring concrete. The additive dosing consists of 2 x 20 l for of the core www.cpi-worldwide.com

A mould-changing crane is installed on the machine for automatic mould changing.

The concrete goods in the new Rewa plant are produced on 1,400 x 1,100 mm steel sheet production pallets from Samjung Industries. CPI – Concrete Plant International – 5 | 2015

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The block making machine was enclosed with a sound insulating cabin for a quiet working environment.

Masa Powertainer

concrete and 2 x 9 l for the facing concrete.

The Masa horizontal PH3000/4500 compulsory mixer can produce 3 m³ of concrete per charge and is therefore very suitable for high-performance block making machines.

PH3000/4500 core concrete mixer with elevator, soft start and 1,200 kg cement scale Masa concrete mixers have proven themselves in practice worldwide and offer the customer very high concrete quality in every grade. Short mixing times and optimized use of energy, water and cement are just a few of the many performance features that Masa is committed to.

Buffer area for steel sheet production pallets

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The core concrete mixer has three mixing stars, which provide for fast homogenisation and thorough mixing of the concrete. The mixer can be opened from two sides via two large doors. This considerably facilitates the cleaning of the mixer.

The aggregates from the silos are measured onto a conveyor belt that places it in the lifting bucket. The elevator is equipped with soft start and brings the aggregates to the upper mixer level. The 1,200 kg cement scale ensures exact cement measurement. S350/500 facing concrete mixer The Masa model S 350/500 mixer impresses numerous users due to the high concrete quality, even with coloured facing concrete. With 0.35 m³ facing concrete per charge, this mixer’s performance is

Fresh products on the wet side

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The curing chamber assembled by HS Anlagentechnik at Rewa has a total of 16 chambers, each with 20 levels, and an additional empty chamber.

matched to the capacity of the XL 9.1 machine. The facing concrete mixer elevator is built similarly to the core concrete mixer elevator, except that the bucket has a correspondingly smaller capacity. The cement scale is adequately sized at 400 kg. The S 350/00 facing concrete mixer has a high-speed agitator which, due to its design and high speed, is capable to a large extent of preventing the formation of material balls (agglomerate formation). The speed can be adapted. The agitator is installed in a stationary position in the frame. The mixer trough rotates. Two modern water dosing systems from Masa, type Aquados, are responsible for the precise dosing of water in both mixers. A special feature of the Masa water dosing is the two radar probes employed. The current moisture content of the mixture is measured during the dry mixing period and the calculated water quantity is subsequently added. Colour-Mix-System with 3 silos and mobile dosing belts Two concrete conveyor belts for the core and facing concrete provide direct transport of fresh concrete to the block making machine. A Colour-Mix-System with 3 silos is installed over the charging hopper of the XL 9.1 for facing concrete. Facing concrete www.cpi-worldwide.com

in different colours from the three silos is placed on the mobile dosing belt as needed, which enables custom Colour-Mix production, opening up a higher-priced paving stone segment. XL model concrete block making machines With modern and matured technology, the XL version represents the top model in Masa’s range of block making machines. Decades of experience and continuous further development flow into the technology of this model series. With the XL machines, Masa promises particularly accurate heights in concrete blocks of every type, very high product quality and short cycle times combined with very high daily production volumes. The standard scope of delivery includes continuous silo level measurement with weighing cells in the core and facing silos, oil temperature control with oil heating and air/oil cooler, proportional pressure control for the hydraulics, frequency-controlled vibration, function visualisation with PC control and 24” TFT monitor and online operating assistance. A mould-changing crane is installed on the machine for automatic mould changing. Various moulds are available that can be quickly changed with the system. For smooth production with consistent quality, the XL 9.1 block making machine is

The finger car is equipped with a lifting mast setting for optimal board use when using every second level

equipped with a pneumatic scraper on the core concrete feed box and a smoothing roller on the facing concrete feed box. All hydraulic drive units are placed together in typical Masa fashion in a single container, the so-called Hydrautainer. The complete electronics are contained in the corresponding Powertainer. 1,400 x 1,100 mm steel sheet production pallets The concrete goods in the new Rewa plant are produced on 1,400 x 1,100 mm steel sheet production pallets from Samjung Industries. Rewa management first became aware of the South Korean company in the German edition of CPI Concrete Plant International. Following the initial contact, the transaction was quickly concluded and Samjung Industries delivered the production pallets on schedule to Rewa’s complete satisfaction. Rewa is convinced that they made the right choice for production. Sound insulating cabin for more pleasant working conditions The block making machine was enclosed with a sound insulating cabin for a quiet working environment. The concrete can be poured into the machine feeding hoppers from above through to roof slides. Elevator and lowerator, each with 14 t load capacity The production pallets with the fresh concrete goods pass out of the sound insulating CPI – Concrete Plant International – 5 | 2015

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A further buffer finger car was installed in front of the elevator on the dry side.

Operating console for the dry side

cabin on a conveyor belt. The distance to the elevator is long enough to build in an optional washing plant. Rewa is still planning this step.

is a self-contained, independent unit that is structurally stable and requires no lateral or upward support.

The elevator and lowerator in the drying chamber each have a load capacity of 14 t and 20 levels with a height of 360 mm. Only every second level is occupied with taller products. The finger car is equipped with a corresponding lifting mast setting for optimal board use in such a case. A buffer finger car is installed in front of the lowerator on the dry side, which enables greater flexibility when storing or retrieving. This ensures a continuous supply of cured products on the dry side.

The aluminium alloys that were specially selected for board supports and stands are formulated to create extremely durable curing chambers. Packaging on trailers for efficient transport to outdoor storage The dry side is built so an optional finishing line can be retrofitted. This step is also supposed to take place soon.

The return transport is equipped with a net installer. The production pallet compacting and extraction device enables acceptance of 1.5 production pallets. The grippers have four sided centring with a vertical turning mechanism. The packaging is equipped with a fast carriage. At Rewa, the stone packages are stacked on trailers that can each carry two stone packages. More and more trailers are joined into a unit, which is then automatically pulled through the hall in cycles by a guide rail in the floor (under floor

Rack system for 9,600 production pallets Masa brought the HS Anlagenbau firm on board for the rack system. The curing chamber assembled by HS Anlagentechnik at Rewa has a total of 16 chambers, each with 20 levels, and an additional empty chamber. The rack system measures 35.0 m x 30.7 m and provides space for 9,600 production pallets. The rack was manufactured as a large chamber system with Masa air circulation system. HS Anlagentechnik supplies curing chambers in a building kit system. The chamber aisles are assembled using a frame construction method and combined with one another. Hence, the number of storage spaces can be planned individually and easily expanded. Each of these assemblies 130

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CONCRETE PRODUCTS & CAST STONE chain conveyor). The complete unit is then towed to the destination at the outdoor storage area by a tractor. There, it is completely unloaded. The package transport is equipped with a cover sheet feeder. The strapping machine ensures automatic horizontal and vertical strapping. All components on the dry side were implemented in accordance with customer wishes and without hydraulics. For years, Masa has consistently relied on electric drives for these assemblies. 왎

Watch a video about the new Rewa concrete block plant: Simply scan the QR code with your smart phone and watch the video! www.cpi-worldwide.com/cpi-tv/video/Masa_Rewa

Masa sponsored the free download possibility of the pdf of this article for all readers of CPI. Please check the website www.cpi-worldwide.com/channels/masa or scan the QR code with your smartphone to get direct access to this website.

FURTHER INFORMATION

Rewa Beton SA Huntheimer Strasse, Rodt, 82 4780 St. Vith, Belgium T +32 80 280818 F +32 80 280819 [email protected] www.rewabeton.be

Masa GmbH Masa-Straße 2 56626 Andernach, Germany T +49 2632 92920 F +49 2632 929211 [email protected] www.masa-group.com

HS Anlagentechnik C.V. Veldkuilstraat 53, 6462 BB Kerkrade, The Netherlands T +31 45 5671190, F +31 45 5671192 [email protected], www.hsanlagentechnik.com

Samjung Industries Co. LTD 363-1, Dukjang-Li, Hunghae-Eup, 791-945 Pohang, Korea T +82 54 260 7777, F+82 54 260 7799 [email protected], www.samjungltd.com www.cpi-worldwide.com

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