Special prefabricated elements specialist Klaus relies on fully individualised automation solutions

Klaus Hoch- und Tiefbau GmbH is upgrading its machines in the precast concrete plant with several automated systems from progress Maschinen & Automation and Tecnocom - companies of the Progress Group. With the individualised reinforcement machines and formwork specially designed for the company in Kissing, the many custom-made stair elements can now be produced even more easily and automatically.

Special designs are the strength of Klaus Fertigteilwerk
Klaus Fertigteilwerk stands out above all in the production of special designs and everything that falls outside the norm, such as winding stairs. The precast plant belongs to Klaus Hoch- und Tiefbau GmbH and thus to the Klaus Group. The precast plant in Kissing has existed since the late 1960s and has developed into a best practice company under the name Klaus, currently employing around 115 people.

Located south of Augsburg, the precast concrete company supplies Bavaria and Baden-Württemberg with high-quality and individual precast concrete elements such as stairs, balconies, façade elements and special designs. The company works almost exclusively for the residential construction sector or private builder-owners, and only to a very little extent for the industrial construction sector.

Customised machines for special design expert
The newly installed Pluristar multifunctional plant from progress Maschinen & Automation combines the functions of an automatic stirrup bender, straightener, and a double bending machine. The Pluristar can process wire diameters from 8 - 16 mm and has a combined straightening system consisting of a roller straightener and a rotar straightening unit. This special combination enables flexible production of stirrups, straight bars and bars with large bends, and can thus cover the entire rebar processing from coil.

Klaus Hoch- precast concrete plantThe custom-built staircase mould system model HT-Tec Plus is a tilting staircase mould with 10 steps, with which individual staircase models can be produced in easily.

In reinforcement processing, the new M-System BlueMesh® mesh welding plant also stands out by its versatility. The specially adapted plant with a small footprint produces customised meshes according to individual specifications, causes no waste due to working directly from the coil and is easy to operate. This ensures a high quality of the product and Klaus’ special designs can be implemented easily and automatically. Some 50 reinforcement cages are produced per day on average. Depending on the order situation, a few more cages can be produced in the plant - 75 baskets in different sizes every day.

Thomas Heubeck, Technical Manager at Klaus Fertigteilwerk, comments regarding the investments made: “Thanks to the new machines, we have made a huge leap forward in reinforcement and can now produce precisely fitting cages for the stair formwork. The base basket then only needs to be attached to the corbel stirrups.” He adds, “For straight stairs, with or without a stair landing, the reinforcement is made to fit exactly, so the iron bender only has to make control measurements.”

The production of winding stairs is somewhat more complex. Here, the mat welding machine produces per metre for the top and bottom layers as well as for the edge baskets. These mats can be cut to size and added for the winding stairs.

In order to further increase the already existing high-quality production standards and the automation rate, Klaus additionally invested in customised stair mould systems from Tecnocom. With this mould systems the formwork work can be realised quickly, flexibly and automatically with very high precision.

“When purchasing the new mould systems, the decision was made in favour of Tecnocom because the products were individually adapted and manufactured to our needs. No other manufacturer could offer that in this way,” says Heubeck.

Klaus Hoch- precast concrete plantThe new mould for staircases of the Ramp-Tec Plus model

A mould system for staircases, model HT-Tec Plus - a special tilt stair formwork with 10 steps - a stair formwork Ramp-Tec Plus as well as a stationary table were delivered.

Klaus Hoch- precast concrete plantWith the new machines from the Progress Group, the special prefabricated elements specialist is now well equipped for enquiries of all kinds.

The automatically adjustable mould ramp for stairs with stair landing - model Ramp-Tec Plus offers an automatic variation of the slope of the ramp and the stair landing. With built-in slope sensors for the variation of the stair rise and by automatically adjusting the slope of the stair landing with electric control, it is possible to adjust the moulds to the respective requirement. In addition, the length of the stairs or the platform size can be set and the faultless surface quality can be produced. The mould surface of the stationary table is sanded to produce precast elements with a high surface quality. The use of side formers enables the production of elements in different sizes and thicknesses. The freshly poured concrete is compacted by high-frequency or pneumatic vibrators. The table is equipped with various heating systems to speed up the curing process.

Klaus Hoch- precast concrete plantThe Pluristar multifunction plant has an automatic changeover from double to single wire processing and an automatic straightening adjustment.

Progress Group as a reliable partner
According to the company, German-speaking, reliable support was very important. The Progress Group meets these requirements. Without language barrier, small questions can be solved quickly and easily. Heubeck says, “Just today I spoke to the support team on the phone for a while. Good communication is essential for ambiguities that need to be resolved quickly.”

The flexible mesh welding plant M-System Blue Mesh® processes reinforcing steel directly from the coil and thus produces with millimetre precision and without waste.

The positive experience of other companies with Progress also influenced the investment decision. Bending, welding, and shuttering can be done by any machine on the market, but the Progress Group was able to convince Klaus Fertigteilwerk with an attractive overall package.
NBM&CW May 2022
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 ...

Elematic Precast Technology Solutions for Building, Industrial and Infra segments

Elematic Precast Technology Solutions for Building, Industrial and Infra segments

Elematic offers a comprehensive range of precast technology solutions for the Building, Industrial and Infra segments. Elematic precast technology enables clients to automate the production of walls, slabs, columns, beams, and stairs, providing an efficient

Read more ...

Advanced Concrete Curing Systems from Kraft Curing

Advanced Concrete Curing Systems from Kraft Curing

Kraft Curing Systems GmbH is offering advanced concrete curing systems that optimize the hardening process of concrete. Kraft Curing’s Advanced Concrete Curing System provides numerous solutions, from vapor-based (steam) systems mainly for the precast

Read more ...

Why Automating Production is the Solution

Why Automating Production is the Solution

Automating the production processes will lead to reduced wastage, fewer errors, more precision, greater safety, and higher quality of the end-products, and in a shorter period of time. First, we need to understand where we stand today as regards industrialisation

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.