Valcke Prefab Concrete unpacks with brand new in-situ concrete plant

Meanwhile, it is running at cruising speed. The unique project represents an increase in production capacity thanks to a feat of homegrown engineering.

Unique construction project in the region

For the execution, we were mainly looking for construction partners in a 20-kilometer radius around Vlamertinge. "To realize this project, we went looking for the best partners," explains Charles Valcke (managing director). "In this exercise, we deliberately included the strongest local players. The collaborations went particularly smoothly because we spoke the same language both literally and figuratively. This proximity is nevertheless an asset."

Strong feat of engineering

The main partner for building the plant was Creus Concrete Solutions. Matthias Creus explains, "Building this type of concrete plant was also a unique experience for us. With Creus, we built two plants of this size in Belgium this year, which certainly represents a nice first for us."

The construction of this project presented many challenges. These were addressed smoothly according to Creus: "The wonderful cooperation with Valcke translated noticeably into the wonderful interaction we had in terms of engineering. The cement silos are all weighted. They are on scales and that on top of a building. Valcke had to adjust the building perfectly to the weight of the silos and vice versa."

"The interaction between Creus' drawing office and ours was very good. We worked entirely according to Building Information Modeling (BIM) by exchanging our 3D models. As a result, for example, all anchor bolts in Valcke Prefab's foundations were perfectly aligned with the position where Creus Solutions provided the holes in their steel structure," adds engineer Kristof Recour (Valcke). "Actually, the project brought together all the departments of Valcke Prefab Concrete. A lot of our people actively collaborated in the realization of this plant."

Increasing capacity

The raw material supply was expanded from 8 to 12 bunkers with 5 cement silos at the plant. A range of more than 200 concrete recipes at 150 m³ per hour can be selected from.

Tom Develter, the plant manager is already enthusiastic about the brand new working environment: "Working in the new plant is night and day different from how it was before. I no longer have to disappoint customers that we cannot deliver more because our capacity can handle much more now. It really is a huge improvement. It is very relaxing to work knowing that there is such a machine behind you. I can count 100% on the system."

Commit to sustainability

Furthermore, the company is fully committed to more sustainable resource management in the production of its own concrete. With the new plant, it will be possible to work with more environmentally friendly cement substitutes in the recipes. "At smaller plants, the capacity is too low to work with cement substitutes. Thanks to the additional cement silos, we can introduce them more smoothly to our customers" explains Kristof Recour.

In addition, the new raw materials bunkers contain, among other things, high-quality concrete recyclate. This is recovered in the recycling park from in-house production waste from the precast departments at the Vlamertinge production site.

Finally, earlier investments were made in a 7 million gallon water buffer basin, along with a treatment plant. These facilities provide a stable supply of water without burdening the surrounding nature.

Ready for the future

 "Our new in-situ concrete plant is designed to be maintenance-friendly but will also be able to adapt quickly to innovative developments in our industry. The plant is thus built in such a way that we are ready for the future" concludes Charles Valcke.