Innovative specialty machines for the precast concrete industry

A fully automatic production line for integral floor plates, a temporary field factory for the production of specific breakwaters for the Afsluitdijk or the installations for the production of housing in a new housing factory. These are some of the many unusual and often innovative special machines from the quiver of KTB-Machinery, part of The Machinery Group. An interview with technical director Thomas ten Brinke about the added value his company provides to the precast concrete industry.

The precast concrete industry faces many challenges. Ten Brinke notices this like no other. "Given the current themes, the industry must green, digitize and above all show resilience. Themes that were also central during the BetonTage 2023 in Ulm, Europe's largest trade congress for the concrete industry," he says. "Such issues frequently come our way. Thanks to our (concrete) technical background and combined expertise with sister company Consmema (exclusive mold builder), we are able to respond like no other. We do not shy away from any challenge." A selection of the many projects recently delivered turnkey by KTB-Machinery, from idea to realization.

Concrete factory Afsluitdijk

Commissioned by construction consortium Levvel, which is engaged in the renovation of the Afsluitdijk, KTB-Machinery has developed and built a temporary field factory for the production of concrete breakwaters. These so-called Levvel blocks weigh 6,500 kilograms each and are specifically designed for the Afsluitdijk. "To this end, we developed an automated carousel in which more than a hundred steel molds rotate in a fully continuous process and 160 pallet wagons move around," Ten Brinke explains. "Approximately every seven minutes a Levvel block was produced. Was indeed, because after the production of the 80,000th breakwater earlier this year, the task was complete. It was definitely an engaging and extremely challenging project for us. In the space of a year, the special machines were developed, built and dismantled again."

Production line integral floor plates

The VBI Integral Floor is a floor concept for serial, ground-level residential construction on an industrial scale including all facilities and installations. "The focus here is on greatly reduced failure costs and construction times," says Ten Brinke. "We have also captured this production process in a carousel concept in which steel molds move around. In horizontal position, the complete installation of the house is applied. Then the mold is tilted and the floor poured vertically. Both the ceiling and floor surface are thus mirror-smooth and immediately ready for painting. The concept reduces construction time from 33 to 20 weeks. As KTB-Machinery and Consmema, we are enormously proud of our contribution to this in all respects challenging project."

Housing Factory

Part of Van Wijnen's housing factory has also been automated by KTB-Machinery. "We have industrialized the process of final assembly of the facade parts as much as possible," says Ten Brinke. "The shell facade section from the factory is grasped by 'our' machine and tilted vertically. In this way, the frames and glazing can be assembled very efficiently, as well as the finishing touches provided right down to the house numbering. From here, the ready-made facade parts are stored on the bag field. This special machine, equipped with an awful lot of tools and resources, is another fine example of out-of-the-box thinking. We go a long way with our clients and are open to thinking outside the box. This not infrequently leads to innovative concepts for clients at home and abroad."

Sustainable building

"We see our customers as partners with whom we want to build sustainably together," concludes Ten Brinke. "We invest in long-term sustainable relationships. Our modern business premises, equipped with a heat pump and a large number of solar panels enable us to produce our innovative solutions completely energy-neutral. Is your production site already ready for the future? We are ready for the future, ready for you to help you with your challenge."