Building Better With Concrete

New circulation plant manufactured by Ebawe Anlagentechnik GmbH - a Progress Group company - revolutionizes production process of Huffcutt Concrete Inc.

Ebawe Anlagentechnik GmbH

Massive modular construction on the advance in USA
In addition to septic tanks, American company Huffcutt Concrete Inc. primarily manufactures individually designed sanitary houses made of solid concrete parts especially for motorways, and now supplies them throughout the country. The manufacturer was able to significantly increase its production capacity by investing in a circulation plant made by the renowned manufacturer Ebawe Anlagentechnik GmbH, a Progress Group company. Since then, it has been able to break into new markets and begin manufacturing structural and architectural wall panels. The new equipment will assist in providing the shortest possible delivery time; and also offers impeccable, extremely stable and durable buildings and panels with architectural designs.

American construction company relies on concrete
Huffcutt Concrete Inc. was founded in 1945 in Chippewa Falls, Wisconsin as a small company that mainly supplied septic tanks to nearby municipalities. In the meantime, Huffcutt has extended its product range to several important product sectors. The focus is on wall panel production while sustaining a strong line of modular buildings, sanitary blocks as well as park and leisure facilities that are sold throughout the country.

Ebawe Anlagentechnik GmbH

Today, Huffcutt is a leading precast concrete company in the USA, supplying quality products to parks, companies, government organisations and private customers throughout the USA. The company attaches particular importance to innovative processes and durable modular buildings made of precast concrete elements. It pays special attention to individual customer requests, be it coloured concrete, architectural designs, or sustainable energy options, and supplies custom-made unique products that are 100% tailored to customer requests.

Ebawe Anlagentechnik GmbH

Last year, Huffcutt invested around 26 million euros in the construction of a completely new production hall at the Chippewa Falls site. The solid walls produced on stationary tables were to be produced quickly, efficiently and with high quality on a circulation plant in the future. Huffcutt chose the German company Ebawe Anlagentechnik, one of seven subsidiaries of the Progress Group, as its supplier. Once all the technical and commercial details had been clarified, assembly began in Wisconsin in autumn 2018.

New circulation plant revolutionises production process
The circulation plant consists of 20 production pallets measuring 4.5 x 12.5 m. Each pallet can carry a weight of 22 t and is equipped with fixed edge shuttering and shuttering attachments. The solid wall shuttering supplied directly by Ratec is placed precisely on the shuttering surface using the Form Master shuttering robot.

Ebawe Anlagentechnik GmbH
The scope of delivery also includes an M-System BlueMesh mesh welding machine from progress Maschinen & Automation, also a subsidiary of the Progress Group. However, this machine was installed at the related company Stein Bros. Steel in Saint Paul, Minneapolis. Stein Bros. Steel is a manufacturer of steel products for the construction industry and also supplies Huffcutt with reinforcement meshes. The reinforcing steel is unwound from the coil and cut and bent according to the data supplied by the ebos® software. This work step is performed by the MSR 16 machine. The mesh welding machine produces the reinforcement meshes just-in-time and precisely for each solid wall. It is the first of its kind in the USA and enables Huffcutt as well as Stein Bros Steel to efficiently produce tailor-made meshes.

The concrete spreader with screw discharge system discharges the concrete evenly on the pallet surface according to the data provided by ebos®. The vibrating levelling beam attached to the concrete spreader draws off the freshly discharged concrete, brushes it to the desired height and then smoothens it. External vibrators additionally perform compaction according to the concrete layer depth. After a resting phase and curing of the concrete surface, fine smoothing is carried out using a power trowel. These work steps result in a very finely smoothed, paintable surface without subsequent post-processing.

After the curing of the solid walls in the stacking rack, consisting of two towers of eleven levels each, the pallets with the cured concrete elements are moved out via the pallet stacker. On fixed rollers and friction wheels, they are driven to the tilting device and brought into an almost vertical position. This facilitates demoulding and lifting processes considerably and enables the walls to be stored in the subsequent installation position.

After completion of the production cycle, the removed solid wall shuttering is cleaned by means of a set down-cleaning device. The pallet passes through a stationary cleaning unit and is given a clean pallet surface by means of spatulas and brushes and is thus ready for the next production run.

The entire circulation plant is controlled via the ebos® control system, eliminating complicated interface problems. Huffcutt benefits from the master computer modules PalBel, WorkPrint and SubLink. PalBel takes over the automatic allocation of the production pallets with concrete parts and allows very simple manual changes afterwards. With the WorkPrint module, worksheets can easily be printed. SubLink is the connection to the shuttering robot, through which the data for the allocation of the pallet surface with shuttering is supplied directly by ebos®.

Ebawe Anlagentechnik GmbH

Concrete modules individually designed
Huffcutt uses the solid walls produced on the new German-made circulation plant primarily for the construction of sanitary houses especially for motorways. These are designed in an architecturally sophisticated way and individually according to the customer requests by the use of form liners. The producer works with different surface designs such as wood, concrete or tile optics, with colours and structures. The small buildings are assembled directly in the plant and completed with the sanitary facilities. The prefabricated modules can thus be transported directly from the plant to the building site and set up there. Thanks to the new production line, Huffcutt is able to offer its modules with the shortest delivery times in the industry. Production is now much faster than the previous manual method and requires less manpower. Huffcutt still has an older production hall in which settling tanks continue to be produced so that no personnel had to be laid off.

Thanks to the new production plant from the Progress Group, the American precast concrete company was able to make its product range more flexible and thus also land orders for the construction of schools and warehouses with solid and sandwich walls.

American construction methods on the test bench
The Huffcutt plant is configured in such a way that it is also suitable for the manufacture of semi-precast elements through expansion with some components. This double-wall plant could revolutionise the construction method there because the construction of properties differs significantly from European construction methods. While in Europe construction is mainly carried out with concrete and stone, the USA relies largely on timber-frame construction with outer walls made of thicker chipboards. The roofs are mostly tacked with roofing felt and walls as well as doors and windows are hardly insulated. For this reason, the houses are mostly equipped with air conditioning systems, which run around the clock in summer. In addition, there are the increasingly frequent hurricanes that uncover entire roofs or completely collapse houses.

It is therefore only a matter of time before the European solid construction method is also applied in the USA. Huffcutt could be a pioneer in this respect and, with its solid concrete elements, could also convince other construction companies of the stable and sustainable concept of building with concrete.
NBM&CW August 2020
3D Concrete Printing: A Look at Challenges & Future of Construction

3D Concrete Printing: A Look at Challenges & Future of Construction

Construction industry is the economic backbone of a country. The productivity of the projects in the construction industry is significantly influenced by formwork systems that consume huge project resources such as time, cost, material and

Read more ...

Boosting Precast Construction with Augmented Reality

Boosting Precast Construction with Augmented Reality

Blending virtual information with the real-world view, AR has become an effective tool in construction management to improve project planning, execution, and delivery. Bhavin Lakhani, Project Controls Specialist Lead, PMP, and CCM

Read more ...

3DXB Group Sets Guinness World Record for Largest 3D-Printed Villa in Dubai

3DXB Group Sets Guinness World Record for Largest 3D-Printed Villa in Dubai

3DXB Group, a leading innovator in 3D printing solutions for the construction industry, unveiled its achievement in making the world’s largest 3D-printed villa in Dubai. This groundbreaking project signifies a pivotal moment in the UAE

Read more ...

Rapidcast Boundary Walls: Best Quality Concrete Precast Textured Walls

Rapidcast Boundary Walls: Best Quality Concrete Precast Textured Walls

Rapidcast LLP brings to you for the first time in India the best quality concrete precast elements such as RCC precast compound walls and RRC precast stormwater UDrains. The new generation Rapidcast boundary wall/fence is a high quality precast

Read more ...

Elematic's Large Precast Concrete Plant for My Home GRAVA Project

Elematic's Large Precast Concrete Plant for My Home GRAVA Project

Hyderabad is witnessing the construction of Asia's tallest towers with a planned built-up area totalling 3.7 million sqm. The two 180-meter towers, each comprising 43 storeys, will be accompanied by six more similar towers. With each tower

Read more ...

Benefits of Shear Keyed Surfaces in Precast Building

Benefits of Shear Keyed Surfaces in Precast Building

Depending on the finish of the concrete surface, different coefficients are assigned by international codes in the calculation of shear resistance. The American Concrete Institute Code ACI318, Nov.19, states the following: Chapter 16.2.1.1 – Transfer of forces by

Read more ...

Revolutionizing Precast Industry with Advanced Tracking of Precast Concrete Elements

Revolutionizing Precast Industry with Advanced Tracking of Precast Concrete Elements

The precast concrete industry is undergoing a transformative change with innovative software solutions that offer enhanced tracking of precast concrete elements. One of these pioneering software solutions is StruSoft’s Impact Precast, which aims

Read more ...

Emerging Trends & Growth of the Prefab Industry

Emerging Trends & Growth of the Prefab Industry

Prefabricated technologies are becoming increasingly popular in the construction industry, particularly for large-scale construction. As prefabricated structures continue to evolve and improve, they are being used to construct warehouses, factories

Read more ...

Precast RCC Structures versus Pre-Engineered Steel Structures

Precast RCC Structures versus Pre-Engineered Steel Structures

A comparative study on Industrial Building Adopting Structural Frames as Precast RCC and Structural Steel Frames with Prestressed Precast Hollow Core Slabs as Flooring Slabs, presented by C. A. Prasad, Director, METEY Engineering Consultancy, Hyderabad

Read more ...

My Home Mega Project Shows Potential of Precast Construction Technology in India

My Home Mega Project Shows Potential of Precast Construction Technology in India

Storey by storey, Asia’s tallest precast towers with a total planned built-up area of 3.7 million sqm are rising towards the sky in Hyderabad. These two 180-meter towers of 43-stories each will be followed by six more similar towers. With each tower

Read more ...

Mekuba: A Leader in Mould Releasing Agents for Concrete

Mekuba: A Leader in Mould Releasing Agents for Concrete

With over 47 years of experience in the petrochemicals industry, and an expert in the formulation and production of mould-releasing agents, Mekuba Petro Products is growing rapidly in the construction chemicals segment with a daily production

Read more ...

Dextra Groutec Coupler - A Unique Solution for Reliable Joints in Precast

Dextra Groutec Coupler - A Unique Solution for Reliable Joints in Precast

Dextra has added yet another customer-centric, innovative, and custom engineered product - the Groutec Coupler - an efficient product that has been qualified and tested successfully on several major infrastructure projects in the recent past. With the

Read more ...

India an Important Market for TOPWERK

India an Important Market for TOPWERK

Sachin Shetty, India Head – Operation & Sales, and Rajesh Jha, India Head - Sales & Market Development, TOPWERK INDIA, discuss the potential of precast concrete construction in India, localization of non-critical components to bring down cost, and the possibilities of digitalization

Read more ...

Vollert: Building A Stronger India with Precast

Vollert: Building A Stronger India with Precast

Vollert India has recently expanded its production capacity in Sikandrabad (UP) India. As a global leader in precast concrete components, systems, and machine solutions, Vollert’s investment in India indicates a growing interest among German companies

Read more ...

Precast India Connector - Helping Precasters Overcome Cost & Time Overruns

Precast India Connector - Helping Precasters Overcome Cost & Time Overruns

Precast India Connections, a new entity of Precast India Infrastructures, has innovated and patented a method of achieving a Dowel-Sleeve connection that functions even in the horizontal direction. Kapilesh Bhate, MD, Precast India Connections, shares

Read more ...

Prensoland Modern Precast Floors Appearance of the iHCS

Prensoland Modern Precast Floors Appearance of the iHCS

Pre-stressed concrete hollow core slabs used for building floors are unidirectional members; they are laid one next to the other until the complete carpet area is covered. In the presence of lateral loads like wind, or due to seismic episodes, they behave

Read more ...

Vollert India Expands Production Capacity

Vollert India Expands Production Capacity

The expansion of the Vollert plant in India marks an important milestone in the company’s commitment to provide high-quality products to customers. With the increased production capacity, the company aims to expand its market share and strengthen

Read more ...

Brimax AAC: An Indian Lighthouse Project from HESS AAC SYSTEMS, Netherlands

Brimax AAC: An Indian Lighthouse Project from HESS AAC SYSTEMS, Netherlands

Brimax AAC Products LLP contracted Hess AAC Systems to supply a new AAC plant in Vadodara, India, with a capacity of 680 cbm/day (expandable up to 900 cbm/day with reinforcement for panel production). This order strengthens Hess´ position as

Read more ...

Vollert India Expands Production Capacity to Cater to Infra Development Sector

Vollert India Expands Production Capacity to Cater to Infra Development Sector

Vollert India, based in Sikandrabad, near Greater Noida (UP) since 2017, is strengthening its commitment to India; it is now expanding its production capacity of precast machinery and components to meet the greater demand from India’s fast

Read more ...

To get latest updates on whatsapp, Save +91 93545 87773 and send us a 'Saved' message
Click Here to Subscribe to Our eNewsletter.