Gulf Construction Online - Precast and fast

The Big 5 - Saudi Arabia

Sommer precast plants ... fully automated and computerised.

Precast and fast

01 February 2012

SOMMER Anlagentechnik Middle East will be unveiling at The Big 5 Saudi next month a new German precast building system that offers a speedy solution to the region’s housing shortages.

The innovative system will be the highlight of its stand at the Saudi event, where visitors can witness first-hand Sommer’s wide technical expertise in manufacturing precast concrete production lines through its display of a range of Sommer machines, Eurobend steel processing machines and Nemetschek Engineering’s precast solution software including SCIA Engineer.

Sommer’s new precast building system consists of double walls and filigree/form slabs that enable the construction of a villa in just seven days, according to Dr Ziad Musa, the company’s general manager.

The product will also be the focus of a seminar to be conducted by Sommer at the Holiday Inn Jeddah – Al Salam on March 12 (10 am to 3 pm).

Sommer Anlagentechnik Middle East, part of Germany’s Sommer Anlagentechnik, was established in November 2006 in Riyadh, Saudi Arabia.

The German parent company has been manufacturing and developing machines and equipment since 1857, and has been utilising this extensive experience to offer clients a complete solution, which involves efficient conceptualisation, design and implementation of production plants for the precast concrete industry.

Dr Musa says Sommer can provide the Saudi and Middle East markets with efficient precast concrete production lines. “Also, based on our extensive experience in the sector, we are able to offer our customers turnkey services starting from designing plant layout to plant operation and erection of precast elements at site. The whole process involves consultation, project planning, production, operation, installation, and after-sales services,”he says.

Sommer has undertaken projects throughout the Middle East for clients such as Mammut in Dubai, UAE, Taameer in Jordan, Barwa in Qatar, and SBS in Saudi Arabia.

Dr Musa expects a real estate boom in the region within the next five to 10 years, particularly to meet the huge demand for housing projects. In this regard, he believes precast technology offers the ideal solution.

“The demand for housing, mainly in Saudi Arabia, cannot be met using traditional building systems and can only be addressed by using precast building systems produced in modern and computerised precast plants. This will minimise the labour requirements and project duration while increasing product quality,” he says.

To meet the demand for housing, Sommer has taken its own initiatives in setting up a precast plant in the kingdom in joint venture with a Saudi investor. The plant is expected to come on line in the next two months.

Sommer’s precast plants are automated and computerised with a pallet circulation system. These units feature a master computer to control all plant stations, shuttering with a magnet system controlled by a robotic system, steel processing machines, concrete distributor compacting station, curing chamber, tilting station, cleaning and oiling machines for pallets and shuttering, and a turning station to produce the new German building system.

These precast plants can produce double walls with or without insulation, and form/half slabs for the new building system as well as other components such as sandwich panels, facade elements, solid walls, stairs, beams and columns, and double-tee slabs.

To ensure a complete and efficient precast production unit, Sommer has also partnered with Eurobend, which has been involved in the manufacture of advanced technology machinery since the mid-1980s. Eurobend specialises in the production of fully-automated machines for straightening, cutting and bending of all types of steel wire (smooth, deformed, recessed or re-bar), mesh-welding machines and mattress-making machines.

“Sommer Middle East and Eurobend are committed to maintaining reliable and technically advanced machinery for the precast concrete industry,” says Dr Musa.

For the design of precast buildings, the company uses sophisticated German design software to ensure the quality of precast elements. In these regard, Sommer is partner to Nemetschek Engineering, the developer of the Allplan precast software. Its software solutions are designed for architects, engineers and precast factories.

These methods and technologies allow precast factories to produce precast concrete elements that perfectly meet the requirements in terms of design, structural integrity and economy. “Structural analysis and design requirements for all precast elements are done through the Scia Engineer software, which is part of the Nemetschek Group,” he says.

Dr Musa continues: “Production in the most economically justifiable manner is essential, and Allplan Precast plays an important role in this regard. It is indispensable in highly automated factories with circulation systems. The software provides the data for the operation of the robots. Wherever applied, Allplan offers the solutions needed to accelerate and improve operations. For example, ‘identifier’ recognises similar parts.”

The company has strengthened its relationship with Nemetschek Engineering and is aiming at furthering Sommer’s precast technology through developments such as mobile field factory (MFF) and the shuttle processing plant (SPP) patents. At the same time, it is looking at setting up new joint ventures with local partners for precast plants.

Sommer Middle East has now set its goal on playing a leadership role in managing German precast concrete plants, making the precast building system the first choice for customers and setting benchmarks for the region’s precast industry. Starting with Saudi Arabia, the company intends to spread its influence throughout the Middle East.

“Sommer also intends to create a major impact on the market by establishing and managing precast concrete plants, transferring Sommer know-how, technologies and integrated computerised systems to the Middle East markets, introducing a new concept in building systems such as Sommer’s double-wall elements and increasing awareness among customers and consultants about the efficiency and reliability of this new system,” says Dr Musa.

“Sommer precast building systems reduce construction time by up to 70 per cent, building cost and manpower by up to 60 per cent, minimise manufacturing faults, maximise quality and efficiency and maintain the highest automation level and tolerance accuracy, using standardised accessories, while enhancing insulation levels, saving energy and using environment-friendly solutions,” he adds.

Sommer Anlagentechnik Middle East can be visited at Stand G44, Hall Two, at The Big 5 Saudi.