On account of a new patented production method, Lithon-plus Steinmanufaktur has succeeded for the first time withthe invention of the "L-Tec System Angle" in the industrialmanufacture of large L-shaped retaining walls with impres-sive advantages: they are formwork-smooth all round andmuch easier to transport, lift and erect. The company tookfive years to develop this new manufacturing method,which it has successfully implemented together with themachine and plant manufacturing specialists for the pre-cast industry Ebawe Anlagentechnik GmbH and TecnocomSpa, both of which belong to the Progress Group.

More than 100 years of concrete experience

Lithonplus Steinmanufaktur, headquar-tered in Lingenfeld, Rhineland-Palati-nate, is a subsidiary of HeidelbergCe-ment AG and Schwenk KG. The com-pany has concentrated their traditionalactivities in the field of concrete prod-ucts since 2004 and can look back onover one hundred years of experience.At 16 locations all over Germany thecompany produces and distributes anextensive range of high-quality concreteproducts for the layout of paths,squares, patios, drives and front gardensof houses. A team of around 600 em-ployees generate an annual turnover ofmore than 120 million euros.

Success with the right philosophy

Apart from a distinct passion for con-crete, the success philosophy in the pastyears has focused on the manufacture ofhigh-quality products and a high level ofcustomer orientation.

Jürgen Rust, section manager for L-shaped retaining walls atLithonplus says: "For us, concrete means unlimited designfreedom and a rich diversity due to an endless number ofpossible shapes and colours. Our passion is to use this free-dom and to turn it with fantasy into convincing product lines."All dealings revolve around strict customer orientation: "Our

goal is absolute customer satisfaction and long-term cus-tomer retention. We wish to achieve that with convincingproducts, smooth processes and the uncompromising imple-mentation of all requirements." One of the most important cri-teria in this context is the manufacture of high-quality prod-ucts. "The machine-manufactured products are therefore pro-duced on modern plants with the latest technology", saysRust.

The innovative L-TEC System Angle

Gregory Trautmann and Wilfried Polle, both managing direc-tors at Lithonplus, recall that the desire to also implementthese high company standards in the development and pro-duction of large L-shaped retaining walls demanded a great

deal of innovative force from the com-pany: "It took five years to develop theinnovative plant for the optimal pro-duction of high-quality concrete ele-ments." The goal was to find an auto-mated alternative to the traditionalmanual production of L-shaped retain-ing walls, often also referred to as sys-tem angles. In addition, the universallyusable L-shaped retaining walls were tohave fair-faced concrete quality allround apart from the face on whichthey stand and - unlike conventionalmanufacturing methods - not exhibitany conicity. Following the long devel-opment period, the result has im-pressed planners and product usersalike. In the development of the L-TecSystem Angle, the company succeededin realising all these goals as well as further innovations:

Easy and uncomplicated handling

The trick is the suspension point of the L-shaped retainingwall, which is placed at the centre of gravity. As a result, theL-shaped retaining wall balances itself automatically duringhandling and is much easier than usual to lift and transport.Setting down on the foundations is quickly done, since en-ergy-sapping alignment and adjustment are largely avoided.

PRECAST CONCRETE ELEMENTS

CPI – Concrete Plant International – 2 | 2018 www.cpi-worldwide.com192

Lithonplus uses new production method for the manufacture of L-shaped retaining walls

Progress Group GmbH, 60549 Frankfurt am Main, Germany

Jürgen Rust, section manager forL-shaped retaining walls at Lithon-plus, is very satisfied with the newL-Tec System Angle and the highlyautomated production plant

06b-Precast_164-203_en_Layout 1 06.03.18 14:30 Seite 192

Progress Maschinen & Automation AGJulius-Durst-Str. 100

I-39042 Brixen Tel. +39 0472 979 100

info@progress-m.comwww.progress-m.com

The newest generation of lattice girder production is:

flexible fully automated without waste

Lattice Girder Welding Machines

The VGA Versa allows fully automatic and just-in-time lattice girder production.

The plant is equipped with automatic lattice girder height adjustment and produces at the highest level of flexibility.

06b-Precast_164-203_en_Layout 1 06.03.18 14:30 Seite 193

Maximum fair-faced concrete quality SB4 all round

The maximum fair-faced concrete quality, class 4, is achievedall round with the L-shaped retaining walls. L-TEC System An-gles therefore also impress as visual highlights and are of in-terest for extended areas of application, e.g. as a wall dividerthat is visible on both sides.

Flawless shaping

Formwork-related conicity is consigned to the past. L-Tec Sys-tem Angles have a constant width over their entire height. L-shaped retaining walls placed alongside one another havethe same joint width from top to bottom. The circumferentialchamfers are reduced and of the same size. The formation ofa dummy joint for 99 cm-wide elements was consciously omit-ted.

Ideal for traffic areas where de-icing salt is used

L-TEC System Angles conform to exposure class XF4, whichmeans that they are suitable for applications where stress dueto the use of deicing chemicals can be expected. This stan-dard ensures planning and implementation security for all en-vironmental conditions. In addition, the exposure class XF4 isprescribed for installation in traffic areas.

Quality products through automated production technology

Following a long and careful examination of various machineand plant manufacturers, Lithonplus chose to cooperate withEbawe Anlagentechnik GmbH and Tecnocom Spa, both com-

panies from the Progress Group, as its partners for the devel-opment of a highly automated production system for themanufacture of the new L-TEC System Angle.

The two partners developed for the first time a special circu-lation plant, tailored to Lithonplus' needs for the productionof L-shaped retaining walls, in combination with specialmoulds with which the production of different L-shaped re-taining walls with a length of 49 cm or 99 cm and heights ofbetween 55 cm and 305 cm was possible without the conven-tional conicity of the elements.

A bespoke seven-stage production process allowed the man-ufacture of the new system angles to be automated to thehighest degree. Following the cleaning and oiling of the spe-cial moulds, the concreting process takes place fully automat-ically with the aid of a fill-quantity monitor and a height-ad-justable concrete distributor that can be adapted individuallyto the different mould heights. Several L-shaped retainingwalls are concreted simultaneously.

The curing of the elements in a special curing chamber andthe removal of the finished parts from the manufacturingprocess are also automated. The high degree of automationenables the company to operate a multi-shift system along-side the two-shift system, resulting in a significant increase incapacity with far fewer staff and much higher quality in com-parison with traditional manufacturing methods.

Automation by the EBOS control system

The EBOS control system is the new centrepiece of the plantand manages all important functions. The system also features

PRECAST CONCRETE ELEMENTS

CPI – Concrete Plant International – 2 | 2018 www.cpi-worldwide.com194

The new production plant allows the most diverse types of L-shaped retaining wall to be produced in a short timeand in high quality.

Together with its partner companies EBAWE AnlagentechnikGmbH and Tecnocom Spa, Lithonplus developed a highlyspecialised circulation plant for the manufacture of L-shapedretaining walls.

06b-Precast_164-203_en_Layout 1 06.03.18 14:30 Seite 194

Echo Precast Engineering N.V.

06b-Precast_164-203_en_Layout 1 06.03.18 14:30 Seite 195

PRECAST CONCRETE ELEMENTS

CPI – Concrete Plant International – 2 | 2018 www.cpi-worldwide.com196

several extended capabilities, such as the automatic manage-ment of the curing chamber, the printout of reports and pro-duction analyses, the graphic performance analyzer for thefurther optimisation of production, the printing of labels andthe management of the storage yard.

Concluding evaluation

Jürgen Rust, section manager for L-shaped retaining walls atLithonplus, is delighted with the successes achieved in thepartnership between Lithonplus and the PROGRESS GROUPcompanies. "We have succeeded in creating a unique prod-uct in combination with an extraordinary, highly automatedproduction plant. Never before has it been possible to man-ufacture L-shaped retaining walls in such a variety and qualityand at such a high speed in a plant. We therefore regard thedevelopment of the market and our positioning in it as beingvery positive for the future." �

Lithonplus SteinmanufakturLithonplus GmbH & Co. KGKarl-Lösch-Straße 3, 67360 Lingenfeld, GermanyT +49 6344 9490, F +49 6344 9491 25info@lithonplus.de, www.lithonplus.de

EBAWE Anlagentechnik GmbHDübener Landstraße 58, 04838 Eilenburg, GermanyT +49 3423 6650, F +49 3423 665200info@ebawe.de, www.ebawe.de

Tecnocom S.p.A.Via Antonio Zanussi 305, 33100 Udine, ItalyT +39 0432 621222, F +39 0432 621200info@tecnocom.com, www.tecnocom.com

Progress Group GmbH The Squaire 15 Am Flughafen60549 Frankfurt am Main, GermanyT +49 6977 044044F +49 6977 044045info@progress-group.infowww.progress.group.info

FURTHER INFORMATION

The new suspension of the Lithonplus L-shaped retainingwall enables even easier and less complicated handling.

On account of their quality and properties, the L-Tec SystemAngles will be able to meet even higher customer require-ments in future.

Phot

o: L

ithon

plus

Gm

bH &

Co.

KG

Phot

o: L

ithon

plus

Gm

bH &

Co.

KG

06b-Precast_164-203_en_Layout 1 06.03.18 14:30 Seite 196