DESIGN, CONSTRUCTION AND INSTALLATION OF SPECIAL PLANT AND MACHINERY FOR INDUSTRY
COMPANY PROFILE
PLAN SRLVia delle Nebbie, 7 - 53043 Chiusi (Siena) ITALY
www.planitalia.it [email protected]
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INTRODUCTION
“PLAN SRL” was founded in 1991 by Mr. Eugenio Lucheroni who currently serves as Chairman.
Over the past years “PLAN SRL” has become an industry leader in the design and manufacture of specialist production systems for the construction materials industry. This success is due in large part to the innovative solutions created by dedicated technical and production staff to satisfy customer needs.
The company has now supplied equipment to over 80 customers in 20 different countries.
Strict attention to European Codes means that all equipment is CE kite marked and is compatible with work-place safety regulations world-wide.
The company has over 90 permanent staff and designs, manufactures and in-stalls all components of each production system, trains client personnel and provides after-sales service, thereby ensuring maximum output and quality for each system.
The current range of products covers a wide spectrum, from sophisticated to highly automated plants for the production of high-tech concrete products such as railway sleepers, extruded hollow-core slabs and long span pre-stressed roof elements to individual machines for production and automation of indus-trial processes.
The company is member of:
FiB (Federation International du Béton);IPHA (International Pre-stressed Hollow-core Association);
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FIB (Fédération Internationale du Béton)
inserire foto membri IPHA pag.3 company pro� le
Commission 6 Prefabrication
Task Group 6.5 - Precast concrete railway track systems
Convener: Darroch (RMC Concrete Products, UK)Members: Albajar (Avisa, Spain), Beluzsar (Pfl eiderer, Hungary), Bilek (ZPSV, Czech
Rep.), Giannakos (Hellenic Railways Organisation, Greece), Kiefer (Creabeton AG, Switzerland), Lucheroni (PLAN SRL, Italy), Malmqvist (Abetong Teknik, Swe-den), Petit (Sateba, France), Salo (Consolis, Finland)
Corr. Members: Campbell (Australia), McQueen (P.J. McQueen Corp., USA)Meetings: Athens (May 03), Basel (Dec. 03), Avignon (Apr. 04), Paris (Oct. 04), Madrid
(Feb. 05), Prague (Jun. 05)
The FIP Commission on Prefabrication published in 1986 the “State of the Art” report on concrete railway sleepers. Since that time many changes and developments have taken place in the railway industry. The industry has adopted increased axle loads and speeds, and now widely uses precast concrete crossing bearers for switch and crossings. The use of slab track incorporating precast concrete is now used in special cases. The precast concrete industry has responded with new designs, more effi cient production methods and the adoption of highly effective quality assurance schemes. New codes of practice covering all aspects of precast concrete railway track prod-ucts from design and manufacture to installation and maintenance have been de-veloped. Methods and procedures have been universally adopted to ensure that the isolated occurrences of ASR and Delayed Ettringite that fi rst came to light in the 1980’s are avoided. There have been trials for railway track products using materials other than concrete.It is considered therefore that an updated state of the art report for precast concrete track products was timely and would demonstrate to the specifIer and end user that precast concrete track systems provide a durable, long lasting and economical solu-tion.
IPHA (International Pre-stressed Hollow-core Association)
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PLAN SRL LOCATION
Currently employs over 90 people in two factories:Factory 1
Factory 2
WHEREYOU CAN FIND US
All MACHINERY sold by PLAN is designed, manufactured and tested prior to ship-• ment in these two factories.
PLAN has shipped over 3000 machines from these factories. •
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PRODUCTS
CONCRETE RAILWAY SLEEPER FACTORIES
PRECAST AND PRESTRESSED CONCRETE ELEMENT FACTORIES
PRESTRESSED HOLLOW-CORE SLAB FACTORIES
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CONCRETE RAILWAY SLEEPERS
PLAN SRL
is the largest pure sleeper factory supplier in the world today and has the widest pos-sible experience in supplying working sleeper factories that fulfi ll client needs.
PLAN has a unique set of skills, not very common in sleeper factory manufacturers:
PLAN makes equipment and factories for concrete railway sleeper manufacturing �as its main business. PLAN has built 15 complete and 5 under construction factories in the last 5 years.
Wide experience in the production of concrete in diffi cult environments.�
In-depth knowledge of pre-stressing, not only as it relates to sleepers. �
Years of “hands-on” experience in sleeper production.�
“One stop shop”. PLAN can provide detailed, in depth advice and service on all �phases of sleeper manufacture:
- Aggregate Handling;- Batch Plant Specifi cations;- Mixers;- Concrete Plant Control System;- Concrete temperature Control;- Sleeper design;- Sleeper curing;- Sleeper storage;
32 successful projects in 15 years� ranging from 20 sleepers per hour to 140 sleepers per hour.
More than 40 straight “1st time” sleeper homologations. �
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CAROUSEL SYSTEM
Plan “carousel” method manu-facturing process is based on a non-stop horizontal or vertical carrousel conveyor featuring a continuous closed cycle. Moulds are moved simultaneously through the plant from one work station to the next in the produc-tion zone with cured sleepers moving along the fi nishing line. At each work station the differ-ent phases are executed, with computerised quality control keeping records of each critical operation. The production phases can be fully or semi-automated depending on customer pref-erence. Using Plan “carousel” method plant it is simple to produce different kinds of sleepers (different dimensions, different tensioning load and rail fastening...) during the same working shift.
MARGAPLAN® SYSTEM
As a result of this experience and in anticipation of strict new EC regulations for pre-stressed concrete in 2000 Plan fi nished development of the new MARGAPLAN® system for post-tensioned, high performance sleepers directed toward inclusion as part of the permanent way of the latest generation of high speed lines being planned around the world. Sleeper manufactured using the MARGAPLAN® post-tensioned system is used throughout the Italian Railway System (RFI) with excellent results, for example the high speed line Milan – Turin and the high speed line Florence – Bologna with the new speed record of 350.8 km/h without vibration.
PLAN was the fi rst plant manufacturer
to have successfully homologated sleepers in complete compliance the newest
European Norms 13230
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PLAN is the only plant manufacturer which has successfully homologated different sleepers using different technologies with the carousel system
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AUTO DATA COLLECTION AND STORAGE
Data of each machine are collected and stored in a Windows® PC with the chance to control the production at distance. Each mould is equipped with a bar-code iden-tifi cation tag.
CONCRETE CURING AUTO DATA COLLECTION AND STORAGE
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BALLASTLESS TRACK
PLAN SRL
also supplies moulds and production
linesfor ballastless track
(also know as “slab track”)applications ranging
from Light Rail Transit to regular rail system
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PLAN SRL
offers various solutions for turnkey factories dependingon the structural systems and production capacities required
by the Client and the availability of local resources.
PLAN makes equipment and factories as its main business;�
Wide experience in the production of concrete in diffi cult environments;�
In-depth knowledge of element design, pre-stressing, handling (in the fac-�tory and at the site), and installation;
Years of “hands-on” experience in precast production and installation;�
“One stop shop”. PLAN can provide detailed, in depth advice and service �on all phases of pre-cast concrete manufacturing:- Aggregate handling;- Batch plant specifi cations and mixers;- Concrete temperature control;- Precast product design;- Precast product curing;- Precast product storage;- Precast product transport;- Precast product installation/erection;
PLAN supplies:
Automated factories for the production of Industrial / Commercial struc-�tures (foundations, columns, beams);
Automated factories and machinery for the production of hollow-core �slabs;
Automated factories and machinery for the production of roof elements;�
Automated factories and machinery for the production of wall panels;�
CONCRETE PRE-CAST ELEMENTS
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PRODUCTION CENTRE FOR COLUMNS
The PLAN solution for the production of concrete columns provides a fast and fl exible system for the production of pre-cast columns with varying sizes, using a minimum of labour and ensuring that the producer can modify the production centre and cast different columns every single working shift.
PLAN production centre allows to produce columns from 500x500 to 800x1000 mm including all the intermediate sections by the use of interchangeable modular bot-tom shutters that are positioned with a simple interlocking system and are adjusted to height, in pre-set positions, by hydraulic actuators. It also allows the producer to place corbels on any side and at any spacing that may be required. This is accomplished by modular infi ll elements which have the shape of the desired corbel and replace the modular shutter elements in the position required. The side shutters are opened and closed by hydraulic cylinders and the bottom shutter moves sideways when the side shutters open, making stripping a stress free operation, both for the pre-cast unit and the operator.
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PRODUCTION CENTRES FOR PRESTRESSED BEAMS
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ROOF INFILL PANEL PRODUCTION
a) Automatic stripping b) Automatic handling
c) Insulation application d) Water proofi ng
e) Steel cladding f) Soffi t painting
g) Automatic packing
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HANDLING SYSTEMS
40 Ton machine for wall panel transport/washing
12 Ton machine for reinforcement cage transport
200 Ton machine for hollow-core slab transport
200 Ton machine for long-span roof element transport
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STRONG BACK BEAMS
12 Ton self-levelling strong back beam for column and beam handling
12 Ton self-levelling strong back beam for wall panel handling
15 Ton self-levelling for special hollow-core slab handling
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PRE-STRESSED HOLLOW-CORE
PLAN SRL
Offers the most cost effective hollow-core production system
in the market.
The PLAN hydraulic extruder is the lowest “life-cycle cost” machine
available (including slip formers)and the initial investment cost is very competitive.
Stressing, stripping, cleaning and handling systems are all highly automated,
easy to use andreasonably priced.
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BED PREPARATION
TECHNICAL SPECSDimensions (meter)• 3.5 x 2.0 x 2.35 (h)Weight• 32 kNExtrusion speed• 0-40 m/minConnection power• Industrial battery 80 VElectrical absorption• (battery charger 5 kW)
Bed cleaning with a rotating brush to remove dust and debris from the •casting bed’s surface (including the rails);
Pulling strands along the casting bed (up to no. 10 strands at the same •time);
Oil distribution (protecting the strands), applying release agent (form •oil) to the casting bed surface;
Bed cover placing and removal•
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TECHNICAL SPECS ST-50 SAWSpeed of cut for longest blade life 650 mm/min for H400 slab section
(2 minute cycle time)900 mm/min for H200 slab section
ST-40 saw capable to cut up to 1200x420mm
ST-50 saw capable to cut up to 1200x520mm
ST-70 saw capable to cut up to 1200x720mm
CUTTING
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SOUND BARRIER PRODUCTION
Cutting machine
Casting machine
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Customername
Country Year Main characteristics
Production system Type of railwaysleepers
IANNARILLI ITALY 1994 Fixed plant 25 sleepers/hour
Pre-tensioned system (button headed wires
with end anchor plates)
FSV 35
CEVIP ITALY 1996 Fixed plant 75 sleepers/hour
Pre-tensioned system (button headed wires
with end anchor plates)
FSV 35
VIANINI ITALY 19961997
Fixed plant 140 sleepers/hour
Pre-tensioned system (button headed wires
with end anchor plates)
High Speed sleepers
VIBROBETON CROATIA 19971998
Fixed plant 70 sleepers/hour
Pre-tensioned system (button headed wires
with end anchor plates)
B70
ICEP ITALY 19971998
Fixed plant 75 sleepers/hour
Pre-tensioned system (button headed wires
with end anchor plates)
FSV35
LODOVICHI ITALY 19971998
Fixed plant (re-novation & up-grading) 90-130 sleepers/hour
Pre-tensioned system (button headed wires
with end anchor plates)
FSV35
PIZZAROTTI ITALY 1998 20032005
Fixed plant (re-novation & up-grading) 70-120 sleepers/hour
Pre-tensioned system (button headed wires
with end anchor plates)
FSV35 – High Speed
SINTA TURKEY 1999 Fixed plant 25 sleepers/hour
Pre-tensioned system (button headed wires
with end anchor plates)
B58
ZAODON-TRADE
UKRAINE 1999 Fixed plant Pre-tensioned system Plant design
EDILE FERROVIRIA
ITALY 1999 Fixed plant 90 sleepers/hour
Pre-tensioned system (button headed wires
with end anchor plates)
FSV 35
MARGARITELLIITALIA
ITALY(Chivasso)
2000 Mobile plant14 turnouts/hour
“MARGAPLAN”Post-tensioned
system
Turnoutsleepers2100 to
4800/6600m length
REFERENCES (Concrete sleepers)
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MARGARITELLI ITALIA
ITALY (Casoli)
2001 Mobile plant75 sleepers/hour
“MARGAPLAN”Post-tensioned system
RFI 230, 240, 260 (High Speed) – Tram sleepers (Pan-drol - Vossloh)
MARGARITELLI I TALIA
QC according to EN 13230
ITALY(Rodallo)
2003 Fixed plant(1st production line)90 sleepers/hour
“MARGAPLAN”Post-tensioned system
RFI 240 –RFI 260 (High Speed)(Pandrol - Vos-sloh)
MARGARITELLI ITALIA
QC according to EN 13230
ITALY(Rodallo)
2003 Fixed plant(2nd production line)60 turnouts/hour
“MARGAPLAN”Post-tensioned system
Turnoutsleepers2100 to 4800/6600 m length
MARGARITELLIITALIA
QC according to EN 13230
ITALY(Rodallo)
2004 Fixed plant(3rd production line)90 sleepers/hour
“MARGAPLAN”Post-tensioned system
RFI 240 –RFI 260 (High Speed)(Pandrol - Vos-sloh
TRAVERSUD(PIZZAROTTILODOVICHI)QC according to EN 13230
ITALY 2005 Fixed plant140 sleepers/hour
Pre-tensioned system (button headed wires with end anchor pla-tes)
RFI 260 (High Speed)(Pandrol - Vos-sloh
LODOVICHIQC according to EN 13230
ITALY 2005 Fixed plant Pre-tensioned system (button headed wires with end anchor pla-tes)
Turnoutsleepers 6.60m length
MARGARITELLIITALIA
ITALY 2005 2 Slab tracks/hour Reinforced Slab track for LRT
THEMOSGREECE 2005 Mobile plant
40 sleepers/hourPre-tensioned system(improved adhesion wires)
TBS1000 Metric gauge slee-pers (Vossloh)B70 (Vossloh
I CEPQC according to EN 13230
ITALY 2006 Fixed plant100 sleepers/hour
Pre-tensioned system (button headed wires with end anchor plates
RFI 230, 240, 260 (High Spe-ed)(Pandrol - Vos-sloh
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LEONHARDMOLL
(Factory IN-FRAFER in Ain
Sefra)
GERMANY(ALGERIA)
2007 Mobile plant 65 sleepers/
hour
Reinforced Twin-block sleepers (future
production of B70 pre-stressed mo-nobloc sleepers)
ITALSLEEPERSQC according
to EN 13230
ITALY 2007 Fixed plant 100 sleepers/hour
“MARGAPLAN”Post-tensioned
system
RFI230, RFI240, RFI260 (high spe-
ed)(Vossloh)
HIS INDUSTRIES PAKISTAN 2007 Mobile plant 50 sleepers/
hour
Pre-tensionedsystem (impro-ved adhesion
wires)
Sleepers length 2750mm
(gauge 1676mm) (Vossloh)
YAPI MERKEZI (ROCLA
CONCRETE TIE)
Turkey U.S.A.) 2008 Mobile plant 50 sleepers/
hour
Pre-tensionedsystem (but-
ton-head wires with end an-chor plates)
B70 (Vossloh)
VOSSLOHFASTENING
SYSTEMS (CXT, LB FOSTER)
GERMANY(U.S.A.)
(workin progress)
Moulds 6 cell gang moulds for
long-line plant
105S-V1 tie(Vossloh)
PRECON SPAIN (Venta de Baños)
2007 Fixed plant (renovation
& upgrading) 40-90 sleepers/
hour
PRECONPLANPost-tensioned
system
FEVE (1900), PR, Al, MR (2600), AM
(2750)
SILVERY DRA-GON
CHINA 2007 Plant for the manufactureof reinforce-
ment
Pre-tensionedsystem
(improvedadhesion
wires)
-
MARGARITELLIITALIA
QC according to EN 13230
FRANCE (work in progress)
Moulds “MARGAPLAN” Post-tensioned
system
M260 PI M450 PI (Fast Clip)
YAPIRAY Turkey (work In progress)
Mobile plant 50 sleepers/
hour
Pre-tensionedsystem (but-
ton-head wires with end an-chor plates)
B70 (Vossloh)
S.A.M SAUDI ARABIA (work in progress)
Mobile plant 80 sleepers/
hour
Pre-tensionedsystem (but-
ton-head wires with end an-chor plates)
Sleepers 2600 mm, 32 Ton axle load (Vossloh)
XKD CHINA (work in progress)
Fixed plant100
sleepers/hour
Reinforced Twin-block sleepers
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Customername
Country Customer name
Country Customer name
Country
AMADONHUNGARY Hungary
HOLLOWCORE SYSTEMS
UK (Factory: Saif Noman Said, KSA)
R.D.B.CENTRO
Italy
AREAPREFABBRICATI
Italy IAPITER Italy REKON-IZHORA Russia
ARGA NAVES INDUSTRIALES
Spain IMPRESA PIZZAROTTI
Italy RESTUCCIA CO-STRUZIONI
Italy
BARRIKADA Russia INPES PREFABBRICATI
Italy SAM. ENGINEERING
Italy
BENTINI COSTRUZIONI
Algeria IPA PRECAST Italy SARBI Russia
CALDANA Italy ITALPREFABBRI-CATI
Italy SERIOPREFABBRICATI
Italy
CENTRO ITALIA PREFABBRICATI
Italy L.C.A. FUTURE SYSTEMS
Italy SHEBH AL JAZERA
Saudi Arabia
CO.PAR.FIN Italy MC-MANINI PREFABBRICATI
Italy S.I.C.E.P. Italy
COOPERATIVADI
COSTRUZIONI
Italy MC PREFABBRICATI
Italy ST.I.ARM Italy
C.S.P.PREFABBRICATI
Italy MABO PREFABBRICATI
Italy STRONG & MIBET EPITOELEMGYAR
Hungary
DELTA SUD Italy MAGNETTI BUILDING
Italy TAV Romania
EDILCEMENTO Italy MAGNETTI PREFABBRICATE
Romania TAV SOLAI Italy
EDILGORIPRECOMPRESSI
Italy MANINI PREFABBRICATI
Italy TECNYCONTA Spain
ESCOSA Costa Rica MANINI PREFABBRICATI
LAZIO
Italy TRAVISUD Italy
F.C.M. Italy OFFICINE PICCINI
Italy TROST Germany
F.I.M. Italy PAMA PREFABBRICATI
Italy VALLEMME PRE-FABBRICATI
Italy
FORNACISCANU
Italy PREFABBRICATI PUGLIESI
Italy VIBROBETON Croatia
FRATELLIBIGNAMI
Italy PRE-FORM Italy VIBROCEMENTO
Italy
GALAZZOPREFABBRICATI
Italy PRELESA Spain VIBROSUD Italy
REFERENCES (Pre-Cast elements)
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GENERALEPREFABBRICATI Italy
PRETENSADOSIDUSTRIALES(SINERCON)
Dominicanrepublic
VIPRECOSTRUCOES
Brazil
GHEDEMPRE-CAST
Eritrea PROFER SYSTEM Italy WEILER ITALIA Italy
G.R. IINDUSTRIES
Belgium PREP Italy
HORMY MECO Spain QUATAR PRECAST
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