new prestressing line for kp1, the recognized specialist ... · precast concrete elements 154 cpi...

PRECAST CONCRETE ELEMENTS

CPI – Concrete Plant International – 4 | 2018 www.cpi-worldwide.com154

KP1, French Industrial Group of First Level specialized in creation of constructive precast concrete systems, haschosen the know-how of Bianchi Casseforme for a new production line of prestressed elements in the factory ofGrigny, Lyon. The new production line includes the follow-ing elements: a steel anchoring structure for strands of 800ton total capacity, a frame with hydraulic deplacement ofthe lateral sides of total length 44 metres, with three interchangeable bases of 50, 60 and 65 cm width, a pair of lateral sides of 44 metres total length, for rectangular R beams up to 135 cm height.

In almost 60 years of existence, KP1 has built its history uponthree pillars: The best know-how of prefabricated buildingsystems; A strategy based on continuous innovation and com-

pleteness of services; Skills everywhere in France, with aunique network of industrial sites and design offices.

Some figures can better give the idea of the size of the group:38 sites in France including 20 production plants, 1700 em-ployees throughout France, building systems for single-familyhomes, collective housing and non-residential buildings, 90patents and 40 brands for to remain leader through innova-tion; 18 design offices all over France, 200 shipments per day.With 60 years of know-how and a strategy focused on inno-vation and services, KP1 manufactures efficient and innovativepre-assembled constructive solutions based on prestressedconcrete components for all types of buildings by buildingon an exceptional network of industrial sites, design offices,agencies and partner traders.

New Prestressing Line for KP1, the recognizedspecialist in precast concrete solutions

Bianchi Casseforme srl, 43045 Fornovo di Taro (PR), Italy

View of the structure for strands anchoring Hydraulic base frame and lateral sides

06a-Precast_132-165_en.qxp_Layout 1 05.07.18 09:17 Seite 154


www.cpi-worldwide.com CPI – Concrete Plant International – 4 | 2018 155

Every day, the KP1 group has a production potential of 2700m² of hollow-core slab, 18000 m² of floor slabs, 4000 linearmeters of girders, 67000 linear meters of beams and 2000 m²of pre-walls.

The production method is of the highest quality since the KP1group has a shared planning and scheduling system to de-liver the right products at the right time, in the right place. TheKP1 group has been a forerunner in the prestressing tech-nique, which allows optimum performance for all installations.The complementarity of the concrete, a material that with-stands the compressive forces, and the steel that withstandsstretching thanks to its elastic properties, allows optimal per-formance for all structures.

The development of this rewarding technique for all construc-tion stakeholders demonstrates every day its many advan-tages on the markets of the individual house, collective hous-ing, industrial and tertiary buildings: anti-crack, anti-breakage,anti-deformation, anti-loss, with reduced thickness, and re-duced weight.

Since its creation, KP1 has placed innovation at the heart ofits strategy. Forerunner in the market, it particularly markedthe building profession for having launched “l’entrevousléger” in 1999 and “le rupteur thermique” in 2004. KP1launches a new era of innovation when it integrates the safety

devices building site to the predalles and hollow-core slabsfrom the year 2010. KP1 products have CE marking, NF certi-fication, CSTB Avis Techniques.

´The safety of work is a main objective of the KP1 groupthrough the 15 % of investments and specific work on behav-ior, leverage of quality and productivity.

All 20 factories of the group also have pooling and transferof skills between factories, constant effort of recruitment andtraining on the quality and the improvement of the processes,as well as regular investment programs in the optimization ofthe manufacturing performances and logistics, heavy repairprograms (concrete plants, production lines ...), integration ofnew processes for new products.

The KP1 group has taken the decision in April 2017 to makean investment in a new production line for prestressed ele-ments in the factory of Grigny, close to Lyon, France. The sup-plier that has been selected has been Bianchi Casseformes.r.l., an Italian family-owned company, established in 1964which is active all over the world with a wide range of servicesand products for the precast industry and industrial buildingconstruction.

The portfolio of the company's products is very wide and cov-ers the following areas: steel moulds for civil, industrial and

Visit us at our booth!

HALL 7 N18




commercial precast buildings, for construction sites, roadsand water projects; vehicles for the distribution of concrete(Mod. Speedy and others); complete plants to produce awide range of precast concrete panels; prestressing systems;magnets and magnetic systems for magnetic mold sides; vibration systems and lifting accessories.

Bianchi Casseforme Srl follows a Quality Management SystemCertificate in accordance to the rule UNI EN ISO 9001: 2015.

The new production line includes the following elements: a steel anchoring structure for strands of 800 ton total capac-ity, a frame with hydraulic deplacement of the lateral sides oftotal length 44 metres, with three interchangeable bases of50, 60 and 65 cm width, a pair of lateral sides of 44 metrestotal length, for rectangular R beams up to 135 cm height.

The steel anchoring structure for strands of total capacity 800ton at 70 cm from the ground is composed by:

At detensioning side: n. 2 columns 3,60 m high placed 1,80m inside the floor pit with internal distance 80 cm betweenthe columns, sized for beams of max height 180 cm; n. 1beam sized for a stressing force of 800 ton that can slide dur-ing the detensioning of the line; n. 1 upper beam sliding hor-izontally, sized for a stressing force of 100 ton (only for upper

strands), fixed to the column and sliding vertically thanks tothe overhead crane; n. 1 base frame where the lower beamcan slide.

At fixed side there is: n. 2 columns with put 1,80 m inside thefloor pit, n. 1 upper beam that can keep a force of 100 ton,fixed to the columns and vertically sliding thanks to the over-head crane; n. 2 protection doors for safety against strands;n. 1 plate indicating the available forces and position of stress-ing loads fixed on the structure.

The groupe of simple effect cylinders for strands detension-ing, with working pressure max 400 bar, stroke 200 mm, safetycollar 180 mm, hydraulic connection 3/8’’, is composed by: n.2 cylinders with force 400 ton, n. 2 cylinders with force 50 ton.

The equipment is completed by an hydraulic unit that controlsthe detensioning cylinders and by an hydraulic installation tolift and lower the safety collars of detensioning cylinders in asafe way without manual operations. The hydraulic base frameL = 44 m placed between the 2 strand anchoring structures iscomposed by: a series of steel structural beams placed oneevery approx 2 metres, on anti-vibration supports and madeby 2 platform made in checker plate on all the length andwidth.

View of the detensioning cylinders and safety collars on thestrands anchoring structure

Demoulding of R-beams




The function of the frame is to be a central base for the inter-changeable casting soffit, between 40 cm and 80 cm width.Total frame width is 340 cm.

On the frame there are the special screw that make the lowerclosure of the lateral sides on the base casting plate. On thebase frame there are as well the hydraulic cylinders and allthe hydraulic plant needed for opening/closing the lateralsides to the base casting plate.

The hydraulic unit for lateral side deplacament is placed atone extremity of the mould, close to one of the anchoringstructures. The unit is actioned by manual levers, equippedwith a flashing light, acoustic alarm and a plate for clear indi-cation of operations to be done. The deplacement of each ofthe 2 lateral sides is independent from the other one.

Below the base frame there are 2 finned pipes diam. 1’’ sizedfor a steam working pressure of 4 bar for accelerated curingof the concrete once poured into the mould.

The base casting plates are placed on the base. Bianchi hassupplied 3 measures of the following width: 50, 60 and 65cm, each one for a total length of 44 metres. The base frameis equipped with steel chamfer 20x20 mm and rubber jointbelow the casting plate to avoid concrete leakage.

The lateral sides have a total length of 44 m (they are madeby 4 pieces of 11 m each), and they can allow the productionof prestressed concrete beams of constant rectangular “R”section, width included between 40 and 80 cm and maximumheight 135cm. These lateral sides are completely made insteel, with a casting plate 6 mm thick reinforced by bent platesand structural profiles.

One lateral side is built in one vertical piece 135 cm high, theother one is made by a piece of 100 cm and a rise of 35cm.The supply of the lateral sides is completed by upper clo-sures, n° 4 lifting hooks and 2 lifting beams that allow the de-placement of the side without its disassembly.

On the lateral sides there are finned pipes diameter 1’’1/2sized for a steam working pressure of 4 bar for acceleratedcuring of the concrete once poured into the mould. The ex-ternal walls of the lateral sides are covered by thermically in-sulating panels.

One of the two sides is completed with 44 linear meters ofworking platform of 60 cm width placed on anti-vibration sup-ports with safety parapet.

The installation of this new production line has been done inSeptember 2017, and the line has reach full capacity after acouple of weeks. �

FURTHER INFORMATION

Groupe KP1M.I.N. Bâtiment D, 135 Avenue Pierre Sémard84000 Avignon, France

KP1 SUD-ESTEtab. De Grigny – Le Sablon1, avenue Marcellin Berthelot69520 Grigny, FranceT +33 0472495969F +33 [email protected]

Bianchi Casseforme srlVia G. Di Vittorio,4243045 Fornovo di Taro (PR), ItalyT +39 0525 400511F +39 0525 [email protected]

Demoulded R-beams in stock during external curing inGrigny factory.


new prestressing line for kp1, the recognized specialist ... · precast concrete elements 154 cpi...

Documents