Construx Weckenmann and KREAR Shape the Future of Construction in Portugal with Innovative Dual-Production Precast Facility

With the increasing demand for efficient, sustainable construction methods in Portugal, Construx Weckenmann has supplied KREAR with a state-of-the-art precast plant to set a new benchmark in industrialized construction. The innovative precast plant, located in Estarreja, features a dual-production system and will begin operations in early 2025, offering enhanced flexibility to meet the evolving needs of the market.

A Benchmark in Industrialized Construction

KREAR is driving innovation in Portugal’s construction sector with one of the few precast plants in Europe to integrate both circulation and stationary production. At the heart of this unique setup is the central shifter, seamlessly connecting two production halls, allowing for maximum flexibility and efficiency. This state-of-the-art plant, stands as a benchmark for industrialized precast concrete production, tackling major industry challenges such as labor shortages, construction delays, and cost volatility.

A Vision for the Future of Industrialized Construction

The KREAR joint venture was founded to transform the construction sector by introducing industrialized precast concrete production for residential and commercial projects. Formed as a collaboration between Secil and Casais, KREAR brings together the strengths of two industry leaders.

Secil, a leading Portuguese group, is recognized for its expertise in the production and distribution of cement, concrete, aggregates, mortars, and hydraulic lime. With its roots in Portugal, Secil has strategically expanded its operations over the past two decades to establish a strong presence in eight countries across four continents.

Casais Group, one of the largest construction companies in Portugal, operates in 17 countries across four continents. Its expansive reach spans markets including Portugal, Angola, Germany, Saudi Arabia, the USA, and more.

The collaboration of Secil’s material expertise and Casais’ extensive construction experience within the joint venture KREAR represents a powerful partnership. Together, they aim to innovate industrialized construction solutions that address the evolving demand for efficiency, sustainability, and quality in the construction sector.

Tailored Plant Concept with Cutting-Edge Technology

Construx Weckenmann’s expertise in engineering and manufacturing was instrumental in bringing this project to life. The plant layout features a two-hall production setup, integrating a fast circulation system in Hall 1 for filigree slabs, double walls, solid walls, and sandwich walls, while Hall 2 offers a flexible workspace for complex elements such as beams, columns, staircases, CREE hybrid timber slabs, and special precast products.

The plant is equipped with advanced automation and transport systems, including a rack operator for pallet handling. A centralized curing chamber ensures optimal precast concrete quality and allows for future expansion. A central shifting system optimizes workflow between both halls.

To start off the production process, the pallets pass through a specialized cleaning and oiling system, ensuring they are perfectly prepared for the next production cycle. Similarly, the shuttering systems are maintained using a modular shuttering cleaner and oiler, preserving their quality and extending their lifespan.

In Hall 1, the shuttering robot automates the precise placement of molds, ensuring minimal errors in the shuttering process. Additionally, embedded parts and steel reinforcement are added at designated buffer stations, seamlessly integrating all necessary components into the process.

A centralized concreting station serves both halls, with a shared concrete spreader and an additional bucket for Hall 2. The high-performance concrete spreader is equipped with a spiked roller discharge, ensuring precise and even concrete distribution. Integrated within this station is the MagVib compaction system, utilizing high-frequency electromagnetic technology to achieve superior concrete consolidation. Furthermore, the production line includes a turning device specifically designed for double wall production. This station also incorporates a shaking station, optimizing the compaction process for different concrete formulations. Both stations utilize energy-efficient technology to deliver high compaction performance, with precise amplitude and frequency adjustments tailored to different concrete mixes. The total pallet circulation system features 26 production pallets with premium steel surfaces ensures superior exposed concrete finishes.

Collaborative Expertise in Planning & Execution

The planning phase of the plant was guided by strong collaboration between key experts, with Construx Weckenmann playing a crucial role in translating production requirements into an efficient and highly automated workflow tailored to KREAR’s needs. Martin Dobler, Projektmanagement für Betonfertigteilbau, supported the process by contributing to the product definition, demand analysis, and initial plant layout concept. The close partnership between all parties resulted in a plant concept designed for long-term success and future scalability.

Production Capacity
In an eight-hour shift, the facility can produce 750 square meters of precast elements, totaling 166,000 m² annually, supporting the efficient construction of large-scale residential and commercial buildings. With the newly established production capacity, KREAR is poised to build up to 1,500 apartments annually, catering to a diverse range of projects, from multifamily and single-family housing to hotels, student accommodations, and public infrastructure. This capacity ensures that KREAR can meet the evolving demands of the construction market effectively.

Empowering KREAR’s Mission with Engineering Excellence

Portugal's housing sector urgently requires innovative solutions to meet growing demand for faster, more efficient, and sustainable building methods. For this transformation to happen, the industry must adopt new technologies and shift its approach to construction.

By seamlessly integrating automation and a flexible production layout, Construx Weckenmann has provided KREAR with the necessary tools to achieve its ambitious growth and sustainability targets. The factory's highly automated processes and precision-driven production methods will help KREAR significantly cut construction timelines while maintaining top-tier quality and reducing environmental impact.

The official launch of KREAR is scheduled for the first half of 2025, it will be another important milestone in the company's strategy. With a strong commitment to delivering advanced industrialized construction solutions, KREAR continues to drive innovation in the sector. The engineering expertise of Construx Weckenmann has been instrumental in transforming this vision into reality, reinforcing the company's position as a leader in the industry.