ConcreTec – Concrete consolidation easier than ever

With ConcreTec you can easily and transparently compact precast concrete in reproducible quality.

ConcreTec is a data-based assistance system for concrete consolidation. The system operators receive objective information in realtime relating to the consolidation process and compaction progress.

The underlying consolidation model not only considers the concrete component’s geometry, however it also takes the features of the fresh concrete into consideration. In addition to this, information about the respective, current process variables, for example the vibration intensity and frequency, feeds into the model during the consolidation process.

What are the benefits of ConcreTec?

Wacker Neuson customer operates Wacker Neuson ConcreTec system.

Simple Handling

ConcreTec can be very easily and clearly operated via a touchscreen. The clear presentation of the respective production situation and the relevant process variables enable the operator to make the correct choice in terms of external vibrators and to follow the consolidation process.

With ConcreTec you will create a manageable workspace for your employees, which contributes to the prevention of fundamental sources of error.

Wacker Neuson ConcreTec system.

Specific Handling Recommendations

With ConcreTec the operator receives a data-based information basis for the objective assessment of the consolidation process. Specifically this means:

  • Display of vibratory level: Should the vibration values lie outside of the favorable range, the external vibrator can be targetedly switched on or off.
  • Display of compaction progress: When compaction progress reaches the desired target value, the consolidation process can be ended.

 

Wacker Neuson employee next to the Wacker Neuson ConcreTec system.

Increased Process Safety

Improve your production processes with ConcreTec, and prevent quality risks. With ConcreTec, the desired consolidation result of the precast concrete element is no longer alone dependent on the experience of an individual, but instead supports decisions on an objective data-basis.

Wacker Neuson customer sitting on his desk operating Wacker Neuson ConcreTec system.

Provision of Process Documentation

Data of the consolidation process is stored for your quality assurance and documentation, and made available in a clear protocol. With this you then have the option to transparently document the compaction process, and to use it as evidence of consolidation.

Wacker Neuson ConcreTec system in a factory hall.

Option to Reduce Noise

ConcreTec aids in the prevention of incomplete concrete consolidation, in addition to the reduction of noise pollution as a result of the unnecessary, intensive consolidation.

Our ConcreTec Models

 

 		    Basic       Advanced       Premium   

Handling:

  • Central control of the vibration system via touchscreen display
  • Display of frequency, activity, total current and vibration duration
 		 x x x
       

Vibration Display:

  • Vibration speed at different measurement points
  • Element-related vibration speed
 		   x x
       

Handling Recommendation:

  • Display of compaction progress
  • Element-specific switch-off indication
 		     x
       

Documentation:

  • Registration of all process data
  • Provision of a consolidation protocol
 		   x x

Frequently Asked Questions

For precise simulation of your consolidation process, the following input-data is important:

  • Element position on the formwork
  • Consistency of the freshly mixed (green) concrete
  • w/c ratio of freshly mixed (green) concrete
  • Element height

Element position on the formwork:

  1. Tap on the “Position” box on the Start screen.
  2. By tapping the diagonal points, you can define the approximate position of the concrete element in relation to the total area of your formwork.
  3. To correct the element’s position, tap on the “Cancel” box.
  4. To confirm the element’s position, tap on the “Finished” box.
  5. In case you have several elements, define the overall size of the individual elements on the formwork.

The input of the correct element position is important for the correct assignment of the accelerometers.

Consistency of the freshly mixed (green) concrete:

  1. Tap on the “Consistency” box on the Start screen.
  2. By tapping on the pre-defined selection boxes, you can select the freshly mixed (green) concrete consistency used.
  3. To correct the freshly mixed (green) concrete consistency, tap on the “Cancel” box.
  4. To confirm the freshly mixed (green) concrete consistency, tap on the “Finished” box.

The input of the correct freshly-mixed (green) concrete consistency is important for the correct calculation of the consolidation work.

W/c ration of freshly mixed (green) concrete:

  1. Tap on the “w/c” box on the Start screen.
  2. By tapping on the pre-defined boxes, you can select the water-cement ratio (w/c ratio) used in your concrete recipe.
  3. To correct the water-cement ratio, tap on the “Cancel” box.
  4. To confirm the water-cement ratio, tap on the “Finished” box.

The input of the correct water-cement ratio is important for the correct calculation of the consolidation time.

Element height:

  1. Tap on the “Height” box on the Start screen.
  2. By tapping on the pre-defined selection boxes, you can select the height of your element (cm). Please round up to the nearest pre-defined element height.
  3. To correct the element height, tap on the “Cancel” box.
  4. To confirm the element height, tap on the “Finished” box.

The input of the correct element height is important for the correct calculation of the consolidation time. Please select the largest height for varying element heights.

Use the integrated touchscreen to activate your external vibrator. The conventional selection of the external vibrator via the protective motor switch in the electrical distribution box is omitted.

This is how it works:

  1. After the element position has been entered, the approximate element position is indicated on the Start screen via a gray area.
  2. On the Start screen, tap on the pre-defined external vibrator circle icon, and in doing so, select the external vibrators to switch on in the element’s immediate surrounding.
  3. The activated external vibrators are presented as a green circle icon; the deactivated external vibrators are presented as a gray circle icon.
  4. To correct the external vibrator selection, tap again on the external vibrator circle icon and deactivate the external vibrator.

Attention: It is possible to switch external vibrators on and/or off, even during the consolidation process.

Use the integrated touchscreen to set the vibration frequency. The usual vibration frequency setting on the frequency converter is omitted.

This is how it works:

  1. Tap on the “Frequency/Hz” box on the Start screen.
  2. The desired vibration frequency can be set in the sub-menu by tapping on the +/- symbols.
  3. Confirm your input using the “x” symbol.
  4. To correct the vibration frequency, tap again on the “Frequency/Hz” box.

Attention: The vibration frequency can also be modified during the consolidation process.

Use the integrated touchscreen to start your vibration system. The usual vibration system start via the Start switch on the frequency converter is omitted.

This is how it works:

  1. After the input has been executed, and the element and system variables have been selected, ConcreTec is ready for use and the vibration system can be started.
  2. Tap on the “Start” box on the Start screen.
  3. The preselected external vibrators start with the set vibration frequency.

Attention: By tapping on the “Stop” box, the vibration system can be manually stopped at any time.

Use the stop function of the integrated touchscreen to stop your vibration system. Using the main switch of the frequency converter, the vibration system can also be switched to zero potential.

This is how it works:

  1. After the targeted execution of the consolidation process, the vibration system must be switched off manually.
  2. Tap on the “Stop” box on the Start screen.
  3. The output power of the frequency converter is switched off, and the activated external vibrators are switched off.

Attention: The vibration system can be manually stopped at any time, both by tapping on the “Stop” box and by operating the main switch on the frequency converter.

ConcreTec supplies important data-based realtime information regarding your consolidation process:

  • Clear presentation of the external vibrators switched on in relation to the element position
  • Duty cycle of the switched-on external vibrator (“Active/sec“)
  • Information about the total power consumption of switched-on external vibrators in an qualitative scale depiction (“Power”)
  • Display of the selected vibration frequency (“Frequency”)
  • Display of the actual, individual vibration speed at measurement points
  • Information about the relevant element -related overall vibration speed in a qualitative scale depiction (“Vibration”)
  • Display of the compaction progress: The compaction progress shows the quantitative development of the consolidation process and provides a switch-off indication for reaching individual compaction targets (“Progress”)

Attention: Responsibility for switching the vibration system off is exclusively incumbent upon the system operator. The compaction progress presents a data-based indication. The vibration system will not automatically switch off.

ConcreTec is an assistance system for concrete consolidation. The vibration system can be exclusively switched off by the system operator.

  1. After the targeted execution of the consolidation process, the vibration system must be switched off manually.
  2. Tap on the “Stop” box on the Start screen.
  3. The output power of the frequency converter is switched off, and the activated external vibrators are switched off.

Attention: The vibration system can be manually stopped at any time, either by tapping on the “Stop” box or by operating the main switch on the frequency converter.

All data collected during the consolidation process are automatically and appropriately stored. All relevant information can be made accessible in prepared consolidation protocols.

The frequency converter with integrated process computers and touchscreen constitutes the ConcreTec system center (Master). The electrical distribution boxes with integrated data collection supply data from the formworks and expand the ConcreTec system randomly (Slave).

  • ConcreTec can be installed in new systems or, after prior inspection, in an existing plant
  • ConcreTec can be configured in any way and adapted to the requirements of your production system
  • The calculation model developed for the “Tilt table” application can be further developed after a preceding analysis phase for additional applications

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