ElectroMech designs an integrated handling solution using advanced crane technology for a precast manufacturing plant in Indonesia. Features include crane synchronization, motion sensors, wireless cameras and an air-conditioned operator cabin.
PT Waskita Beton Precast Tbk (WSBP) was formally established as a subsidiary of PT Waskita Karya (Persero) in the year 2014. WSBP is the largest producer of precast and ready-mixed concrete products in Indonesia. The company has successfully executed various projects such as toll roads, highways, bridges, skyscrapers as well as river revitalisation. WSBP manufactures different types of precast products like concrete electric poles, concrete foundation – spider web type, voided slabs, deck slabs, square piles, L-Gutters, half slabs, pier-heads, PC-T girders, box girders, moveable concrete barriers, CCSP, FCSP, ready-mix, full slabs, concrete railway sleepers, spun pipes, etc.
WSBP was in the process of developing a new bay in their existing plant at Bekasi, Jawa Barat, Indonesia. The new expansion was specifically designed to manufacture large-sized precast segments required for bridge construction. The plant required several cranes for handling raw materials, heavy moulds and precast segments through the various stages of manufacturing, and at the storage yard for stacking and loading precast segments onto trucks/trailers. There was an additional requirement for a crane with a suitable attachment for handling sand/gravel at the concrete mixing plant.
Considering the critical nature of precast segments and their sizes and weights, the WSBP plant is designed to ensure high levels of safety. In view of this, WSBP insisted upon certain features for the new cranes. Usually, the long and heavy precast sections are handled using two or more cranes. To ensure jerk-free and safe handling, it is essential to synchronize the operations of such cranes.
Considering the long hours of working, the cranes were to be fitted with operator cabins giving a comfortable view of the segments being handled. Productivity and safe operation of cranes were top on the agenda of WSBP. They were looking for a competent solution provider who could meet their requirements and had relevant experience in manufacturing such cranes.
After a thorough evaluation of the entire manufacturing process and storage yard at the precast plant of WSBP, we recommended using 13 cranes. Integration of the entire handling in the precast shop and outdoor yard of the new facility was possible using a combination of different types of cranes. Out of this, 9 cranes of Double Girder EOT type for manufacturing, 2 cranes of Double Girder Gantry type for storage yard and 2 gantry cranes with grabbing bucket for concrete mixing area were recommended
All the cranes are designed with a few peculiar features such as:
Additionally, to ensure safe, tilt-free handling of long and heavy precast segments, a few cranes are synchronized for tandem operation.
For the concrete mixing area, we have provided two gantry cranes with grab buckets. This specialised arrangement helps in lifting and pouring sand and gravel into the concrete mixer.
Solution from ElectroMech has helped WSBP in meeting their goals precisely.
Total number of cranes: 13
| Sr. No. | Type | SWL | Span | Height Of Lift | Total Nos. |
|---|---|---|---|---|---|
| 1 | DG EOT | 100t | 43.8m | 0.0m | 4 |
| 2 | DG EOT | 53t | 43.8m | 10.0m | 4 |
| 3 | DG EOT | 10t | 43.8m | 10.0m | 1 |
| 4 | DG Gantry | 53t | 45.0m | 10.0m | 2 |
| 5 | DG Gantry with Grab Bucket | 53/53t | 53.0m | 10.0m | 2 |
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