CSR Hebel: a wide-ranging portfolio with tradition

CSR Hebel can count on a highly experienced local technical and engineering support team. Hebel has developed a patented hoisting solution, making it much easier to install boundary and intertenancy walls in areas with limited access. The company has about 120 employees and offers innovative building solutions that are strong, versatile and sustainable. Hebel panels are high-performance products containing steel reinforcement for added strength with an anti-corrosion layer on the steel for maximum durability.

CSR Hebel has been producing AAC since 1990, when the first line was commissioned at Somersby, using original Hebel (flat-cake cutting) production technology. Throughout the years, CSR Hebel has evolved into a leading building solutions provider by manufacturing high-quality AAC panels that converted many buildings around the country into fire-proof, sound-proof and attractive constructions. As a result of an increasing demand for sustainable and efficient construction, CSR Hebel recognized the opportunity to expand with a second production facility. For this highly customized turn-key AAC project, CSR Hebel engaged the Dutch company Aircrete Europe to develop a versatile, innovative and high-quality manufacturing facility, specifically designed for AAC panel production.

Convinced by reliability

The fact that the choice fell on the customized cage welding plant from Progress Maschinen & Automation, one of the companies in the Progress Group, was no accident. "The reason for our partnership with Progress is the reliability of the machines and services", says Engineering and Reliability Manager Tim Grabham. "We felt Progress had expertise in mesh handling that we had not seen with any other supplier and this is what we needed for our new plant. Building growth has been very strong in both the low-rise housing and multi-residential market, and very strong in the high-rise apartment segments. We are experiencing a slowdown in all segments due to Covid 19."

The entire machine was designed in collaboration with Progress engineers to meet the requirements of the new plant. The new cage welding plant is located near Sydney in Australia and was built for the cost-effective manufacture of bespoke reinforcement mesh for AAC applications. The M-System AAC does work 2 to 3 shifts per day. The daily output is approx. 4000 meshes per day.

The high-performance cage welding plant M-System AAC

Two fully automated Twin-MSR straightener and cutters produce the line and cross wires for the mesh in the required lengths, quantities and diameters. The wires are then automatically transferred to the welding gantry. The resistance spot welding gantry is equipped with multiple welding heads whose computer control system allows the programming of welding parameters according to different wire diameters. While one pair or single meshes are being welded with connector bars made by another JIT working progress machine, the stork takes the next meshes and places these in a similar line adjacent to the first one in order to keep to high-speed volumes required. During the various handling processes the welding gantry welds already the next meshes. The integrated progress control system facilitates CAD-CAM input from a master computer and enables system monitoring and error diagnosis.

The company’s focus on quality, safety and innovation – together with the quality and performance of the AAC applications being manufactured at the plant – has seen CSR Hebel become a preferential contractor for builders, developers, resellers and installers, and a formidable supplier in the construction industry of Australia and New Zealand.