Welcome to the world of RATEC! The development and the production of intelligent formwork solutions for the production of precast components – that has been the core of our brand since our founding in 1994. It has not lost anything in terms of timeliness and has instead become more current. This year we celebrate the 25th anniversary of our company and are pleased about a very success- ful business development, one that makes us optimistic for the future. We are particularly proud, however, that we will be able to present to you our new modular mould kit which glowingly completed its baptism by fire at a project in Singapore. We are convinced that with this new approach we can generate entirely new momentum for the precast concrete industry and are of course extremely excited to see your reaction. This ground- breaking development was made possible only on the basis of our com- petent, interdisciplinary development team that is responsible for this as well as for all other innovations that we will present to you in the pages to follow. We hope you enjoy the stories with many new and innovative ideas! Your The mould kit principle guarantees a high degree of flexibility. With it, even complex details can be executed without difficulty. And it is conven- tionally filled from above. This means that the modular formwork can be easily integrated into existing pro- ductions. The special feature of the new development is, on the one hand, the shrinking mechanism, for which a patent application has been filed and with which, in the same working step, the room element is lifted and the inner core is shrunk. Groundbreaking new development: flexible mould kit for room cells To be able to offer an adequate solution also for lower quantities in modular construction, RATEC has designed a new formwork solution. The innovative formwork tool kit allows for optimal flexibility. 3D explosion On the other hand, the formwork has a modular design. The core and the outer sheets consist of various standardized parts that can be con- verted when needed, thus allowing for different room dimensions. As a result, the formwork can also be applied efficiently even when the number of the room types to be produced is limited. The new flexible 3D mold has already been used successfully in Singapore and will be presented to a broad specialist audience for the first time at bauma 2019. The shrinkable window solution is a further innovation. In Singapore, a total of four of the new modular moulds were installed from which 22 different types of room elements and bathroom units were produced for the construction of an 8-storey building. In the stronger economies of Latin America with correspondingly higher wages, the importance of more efficient production technologies is increasing so that urgently needed affordable housing can be created. Innovative, practically-tested pro- Precast solutions for South America View on the state-of-the-art production line in Panama duction technology for the precast sector is thus becoming essential. In Panama, a modern pallet circula- tion system for the production of precast components was recently put into operation. The system mainly produces massive elements for residential construction and has already been prepared for an expan- sion to include production of double walls. Capacity is at 500 square meters of massive wall per shift. Layout planning, execution planning and commissioning were the respon- sibility of Reymann Technik, an associate company of RATEC GmbH. The shuttering elements are fully automatically placed by robot Headquarters Germany RATEC GmbH Karlsruher Straße 32 D-68766 Hockenheim Phone: +49 6205 9407-29 Fax: +49 6205 9407-30 E-Mail: [email protected] Headquarters USA RATEC LLC 6003 126th Ave North Clearwater, FL 33760 Phone: +1-727-363-7732 Fax: +1-727-363-7463 E-Mail: [email protected] www.ratec.org As an engineering office, the com- pany operates as an independent consultant and thus ensures compre- hensive planning to the advantage of the customer. Baumax, an association of various Chilean specialists, installed the first automated circulation system for the production of reinforced concrete elements in Chile. For the customer’s construction system, RATEC develo- ped a formwork suitable for use with robots with integrated rope loops, but also joint recess profiles for attachment to the formwork or the pallet to which rope loop boxes can be individually attached. For the formwork with integrated rope loops, this is kept as a reusable PE insert in Andreas Reymann Jörg Reymann Asia RATEC ASIA Pte. Ltd. 32 Sungei Kadut Way #02-01 728787 Singapur Phone: +65 6363 1682 Fax: +65 6363 1692 E-Mail: [email protected] Spain/Latin Amerika RATEC S.L.U. C/ Caspe, 12, 1° G E-08010 Barcelona (BCN) Phone: +34 93 4693036 Fax: +34 93 3917947 Mobile: +34 610 702436 E-Mail: [email protected] A finished module the shuttering profile. For the exe- cution of corner joint connections in the element, a magnetic joint recess profile and a correspondingly adapted reusable magnet box with integrated loop for attachment to the profile were developed. RATEC pump technology for infrastructure projects worldwide The upcrete® technology developed by RATEC has established itself as an effective solution for the production of particularly complex precast elements. The core of the technology is the UPP100 concrete pump and the upcrete® pumping process by which air is pressed up and out of the formwork and air pockets in the concrete are nearly completely eliminated. As a rotary pump and in contrast to piston pumps, it allows for a precise dosage in the flow of concrete and an optimal adjustment of the filling pressure. It also nearly eliminates a potential deformation of the formwork or a shifting of built-in components. The upcrete ® pump technology has been able to prove its performance in various projects throughout the world in recent years: The Australian city of Melbourne wants to provide relief to its tense traffic situation with a new elevated railway line. The upcrete ® pump technology was put to use for pro- duction of the roughly 350 supporting elements for the SkyRail with highly complex geometries. A concrete filling connection developed by RATEC allowed for the production of elements with varying heights in a formwork with an adjustable flooring. In China, upcrete ® is used for the production of wind turbines. In order to achieve greater heights with its wind masts, Jinke New Energy, a leading provider of renewable energy in China, decided in favor of a construction from prefabricated concrete elements. With the use of the upcrete ® tech- nology, it was possible to meet all requirements: efficient filling of the formwork with a very tight rein- forcement, optimization of the surface quality, freeing up of crane capacities for other tasks in the precast plants. In Ireland, upcrete ® pump technology is used by a customer for the pro- duction of shaft elements. The elements are used as weighbridges or to contain waterways below roads and rail lines. The use of upcrete ® ensures the top quality of the concrete surfaces in every respect. This means that cost-intensive finishing work on the elements is avoided. In addition, crane capacities were also freed up here that can be put to use for other purposes. Elements for SkyRail Melbourne: the diverse recesses on the tops of the elements meant that a filling from above was not possible. The UPP100 rotary pump in a mobile configuration ensures optimal production processes.
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Welcome to the world of RATEC! The development and the production of intelligent formwork solutions for the production of precast components – that has been the core of our brand since our founding in 1994. It has not lost anything in terms of timeliness and has instead become more current. This year we celebrate the 25th anniversary of our company and are pleased about a very success- ful business development, one that makes us optimistic for the future.
We are particularly proud, however, that we will be able to present to you our new modular mould kit which glowingly completed its baptism by fire at a project in Singapore. We are convinced that with this new approach we can generate entirely new momentum for the precast concrete industry and are of course extremely excited to see your reaction. This ground-breaking development was made possible only on the basis of our com-petent, interdisciplinary development team that is responsible for this as well as for all other innovations that we will present to you in the pages to follow.
We hope you enjoy the stories with many new and innovative ideas!
Your
The mould kit principle guarantees a high degree of flexibility. With it, even complex details can be executed without difficulty. And it is conven- tionally filled from above. This means that the modular formwork can be easily integrated into existing pro-
ductions. The special feature of the new development is, on the one hand, the shrinking mechanism, for which a patent application has been filed and with which, in the same working step, the room element is lifted and the inner core is shrunk.
Groundbreaking new development: flexible mould kit for room cells
To be able to offer an adequate solution also for lower quantities in modular construction, RATEC has designed a new formwork solution.
The innovative formwork tool kit allows for optimal flexibility.
3D explosion
On the other hand, the formwork has a modular design. The core and the outer sheets consist of various standardized parts that can be con-verted when needed, thus allowing for different room dimensions. As a result, the formwork can also be applied efficiently even when the number of the room types to be produced is limited.
The new flexible 3D mold has already been used successfully in Singapore and will be presented to a broad specialist audience for the first time at bauma 2019.
The shrinkable window solution is a further innovation.
In Singapore, a total of four of the new modular moulds were installed from which 22 different types of room elements and bathroom units were produced for the construction of an 8-storey building.
In the stronger economies of Latin America with correspondingly higher wages, the importance of more efficient production technologies is increasing so that urgently needed affordable housing can be created. Innovative, practically-tested pro-
Precast solutions for South America
View on the state-of-the-art production line in Panama
duction technology for the precast sector is thus becoming essential.
In Panama, a modern pallet circula-tion system for the production of precast components was recently put into operation. The system mainly produces massive elements for residential construction and has already been prepared for an expan-sion to include production of double walls. Capacity is at 500 square meters of massive wall per shift.Layout planning, execution planning and commissioning were the respon-sibility of Reymann Technik, an associate company of RATEC GmbH.
The shuttering elements are fully automatically placed by robot
Headquarters Germany RATEC GmbHKarlsruher Straße 32D-68766 HockenheimPhone: +49 6205 9407-29Fax: +49 6205 9407-30E-Mail: [email protected]
Headquarters USA RATEC LLC6003 126th Ave NorthClearwater, FL 33760Phone: +1-727-363-7732Fax: +1-727-363-7463E-Mail: [email protected]
www.ratec.org
As an engineering office, the com-pany operates as an independent consultant and thus ensures compre-hensive planning to the advantage of the customer.
Baumax, an association of various Chilean specialists, installed the first automated circulation system for the production of reinforced concrete elements in Chile. For the customer’s construction system, RATEC develo-ped a formwork suitable for use with robots with integrated rope loops, but also joint recess profiles for attachment to the formwork or the pallet to which rope loop boxes can be individually attached. For the formwork with integrated rope loops, this is kept as a reusable PE insert in
Andreas Reymann Jörg Reymann
AsiaRATEC ASIA Pte. Ltd.32 Sungei Kadut Way #02-01728787 SingapurPhone: +65 6363 1682Fax: +65 6363 1692E-Mail: [email protected]
Spain/Latin AmerikaRATEC S.L.U.C/ Caspe, 12, 1° GE-08010 Barcelona (BCN)Phone: +34 93 4693036Fax: +34 93 3917947Mobile: +34 610 702436E-Mail: [email protected]
A finished module
the shuttering profile. For the exe- cution of corner joint connections in the element, a magnetic joint recess profile and a correspondingly adapted reusable magnet box with integrated loop for attachment to the profile were developed.
RATEC pump technology for infrastructure projects worldwideThe upcrete® technology developed by RATEC has established itself as an effective solution for the production of particularly complex precast elements.
The core of the technology is the UPP100 concrete pump and the upcrete® pumping process by which air is pressed up and out of the formwork and air pockets in the concrete are nearly completely eliminated. As a rotary pump and in contrast to piston pumps, it allows for a precise dosage in the flow of concrete and an optimal adjustment
of the filling pressure. It also nearly eliminates a potential deformation of the formwork or a shifting of built-in components.
The upcrete® pump technology has been able to prove its performance in various projects throughout the world in recent years:
The Australian city of Melbourne wants to provide relief to its tense traffic situation with a new elevated railway line. The upcrete® pump technology was put to use for pro- duction of the roughly 350 supporting elements for the SkyRail with highly complex geometries. A concrete filling connection developed by RATEC allowed for the production of elements with varying heights in a formwork with an adjustable flooring.
In China, upcrete® is used for the production of wind turbines. In order to achieve greater heights with its wind masts, Jinke New Energy, a leading provider of renewable energy in China, decided in favor of a construction from prefabricated concrete elements.
With the use of the upcrete® tech-nology, it was possible to meet all requirements: efficient filling of the formwork with a very tight rein-forcement, optimization of the surface quality, freeing up of crane capacities for other tasks in the precast plants.
In Ireland, upcrete® pump technology is used by a customer for the pro- duction of shaft elements. The elements are used as weighbridges or to contain waterways below roads and rail lines. The use of upcrete® ensures the top quality of the concrete surfaces in every respect.
This means that cost-intensive finishing work on the elements is avoided. In addition, crane capacities were also freed up here that can be put to use for other purposes.
Elements for SkyRail Melbourne: the diverse recesses on the tops of the elements meant that a filling from above was not possible. The UPP100 rotary pump in a mobile
configuration ensures optimal production processes.
The simplest way to produce a 3D room element is the use of a fixed inner core with draft angles. This variation, however, is only suitable when it is possible under structural and aesthetic requirements, for the production of garages or substations, for example.
Flexible new 3D mould for substationsRATEC is developing a new intelligent mould solution that allows for the production of two sizes of substations in different configurations with a single formwork.
For a customer in Germany, RATEC developed a new intelligent form-work solution that allows the client to produce two sizes of substations with a single formwork, and that in different designs. To this end, the solid core and the movable outer sheets can be quickly converted for the respective other size.
Various attachments can be used to form the interior walls and the necessary recesses, depending on the variation.
The movable outer sheets can be quickly converted for the respective other size, as can the solid core.
A substation stands ready for delivery.
The various interior workings of the stations are achieved with the help of interchangeable attachments which are securely held in place in the core by a hydraulic tensioning device. More than 20 different attachments make it possible for the customer to access a broad program of differing variations.
Previously the conversion from one variation to another took up to a half working day, now the switch from one attachment to the other can be carried out in about 20 minutes.
RATEC in the United States
RATEC has been present with a subsidiary in the United States for more than 20 years. Administration and production of RATEC LLC are located in Clearwater, Florida. Here, all products are specifically manu- factured for the North American market, including tilting tables, pre- stressing beds for prestressed concrete elements, battery formwork as well as special formwork solutions for retaining walls, beams, supports and stairs.
This ensures proximity to the cus- tomer as well as a successful symbiosis between the quality demands of “German engineering” and a proud production “Made in the USA”.
RATEC LLC develops formwork tables and shapes specially for the North American market, for example for prestressed precast components.
New battery formworkin the United States
In connection with a major construc-tion project for rainwater retention in Los Angeles, RATEC LLC built a further battery formwork for the production of special elements for Jensen Precast. This is a vertical battery formwork with three pockets that are filled from above. The net size of 10.00 by 2.40 meters allows for use as a twin pocket for the production of elements of up to 4.90 by 2.40 meters. Depending on the concreting, up to six components can be produced in this way. The wall thickness can be 20, 25 or 30 centimeters.
“As a new tooling partner Ratec really performed and allowed us to meet the project schedule”, empha-sizes Jeff Friedmann, Chief Operating Officer at Jensen Precast. “Ratec supplied a battery mold for flat slabs that exceeded Jensen Precast‘s product quality and labor efficiency expectations.”
The vertical battery formwork with three pockets is filled from above.
The formwork meets the strictest demands in terms of quality and efficiency.
RATEC Asia: after two years firmly established
RATEC Asia was founded at the be- ginning of 2017 in order to accelerate development of the market of the future in Asia. Proximity to the cus- tomer makes it possible to deliver more efficient advice and faster ser- vice. In a spacious showroom, visitors have an opportunity to view the outstanding functionality of the RATEC magnetic formwork solutions.
After a little more than two years, the new location in Singapore has firmly established itself and, with its competent team, developed into a first point of contact for our custo-mers in Asia. Here is a look back at a number of project successes:
For a Singapore-based customer, a flexible and simple solution was developed to prefabricate relatively complex precast components direct-ly on the construction site. To date, the company has not produced precast components, instead procu-ring them from precast plants. In order to be able to operate more flexibly, it wanted to find its way itself into prefabrication.
For the production of individual elements (beams, columns, ceilings), RATEC has combined two new systems – the UAR Adapter and the Easy From formwork system – thus optimally meeting the needs of the customer. A particular challenge in this regard is the penetrating rein-forcement and the complex geometry of the elements – a very common problem in Asia. There had previously not been an optimal economical solution, other than the use of an in situ formwork or more expensive traditional 3D formwork. For this special problem, RATEC developed the UAR universal adapter, which has already been successfully put to use in other projects in Asia.
All other formwork tasks are assu-med by the Easy Form System, which is absolutely flexible in terms of length and height and which can be expanded when necessary.
The Innoland Development Corpo-ration in the Philippines was also impressed by the solution and is using it for prefabrication of their components directly on the cons-truction site. In addition to formwork solutions, planning and consulting services are also increasingly in demand. Another customer in the Philippines was supported in the development of a concept that al- lowed them to begin precast produc- tion with a manageable investment.
AT A GLANCE:
The Easy Form formwork system has no problem handling reinforcement …
… and precast production directly on the construction site.
Our subsidiary, MTK Magnetfa-brik Solingen, puts a great deal of passion into the development of customized magnet solutions for industrial applications.Since 2010, MTK has been a fixed part of our group of com-panies and has focused on the development and production of permanent magnets for the precast industry. As a result of the permanent further develop-ment of the magnet materials that we are familiar with today, MTK is repeatedly coming up with new and interesting approa-ches for practical applications, for example permanent lifting magnets.www.mtk-magnetfabrik.de.
RATEC has once again set a record for the installation of integrated magnets in its form-work systems.More than 100,000 neodymium built-in magnets from subsidiary MTK in Solingen were integrated into RATEC magnet formwork in 2018 – more than ever before.The built-in magnets are the core of each magnetic formwork com- ponent from RATEC.
News from Peru – 2nd modular housing plant orderedFollowing the successful Modular Housing Project in Ica, Peru, RATEC recently won an order for the customer’s follow-up project in Northern Peru. Once again, a complete upcrete® system for the production of room modules was ordered.
RATEC scores in China:Over the course of the past two years, RATEC has equipped more than 2,000 circulation pallets for new plants of the Chinese project developer and investor MyHome with its filigree form-work type RT U60 Pro.
Special solutions for elements with protruding reinforcementFor such special solutions, RATEC can draw on a strong development department of its own
For a customer in Austria, a form-work solution suitable for use with a robot was developed in order to produce elements with protruding reinforcement and floor supports. The objective is to significantly reduce the manual effort and the use of wooden formwork.
The solution that was developed is one that consists of standardized magnetic shuttering profiles and a special floor-bearing profile with slits for the reinforcement.
The magnetic shuttering elements are profiled with a round shear key. They can be set using gripping heads with the help of a traverse or by a formwork robot, the floor-bearing profiles are transported with the help of an electro-magnetic handling device.
It was important that these special shuttering elements can use the same interface for formwork transport and formwork cleaning, as is the case with all other automated formwork.
Formwork with floor-bearing case and finished element
A suitable hydraulic deshuttering aid was also designed and delivered.
For special solutions such as this, RATEC can draw on a strong devel- opment department of its own that has an interdisciplinary staff with mechanical engineers, construction engineers and application technicians from throughout the precast industry. In close cooperation with the custo-mer, special solutions are developed that prove themselves to be effective from the first day forward in the pre-cast plants and that make a notice- able contribution to improving efficiency.
Formwork with shear key and reinforcement penetration and finished element
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