LEADERS
THE ART OF SHAPING CONCRETE
SCHLÜSSELBAUER TECHNOLOGY – AUSTRIA
The Dream Generator symbolises the idea that creativity and innovation are infinite.
The rural town of Gaspoltshofen in Austria is home to Schlüsselbauer Technology. Far from making keys – as the name might suggest - this third-generation family business specialises in building unique machines for concrete plants worldwide.
Arriving at the site, the company’s new facility immediately catches the eye. In front of the entrance, a kinetic sculpture known as the Dream Generator rises into the sky. It symbolises the idea that creativity and innovation are infinite. Just as Schlüsselbauer is constantly evolving and exploring new visions, the Dream Generator moves with the forces of nature.
“For our customers in the concrete industry, we develop, design and manufacture machines that produce concrete pipes, pressure and jacking pipes, shaft components, and a wide range of infrastructure elements,” says Marketing Manager Lisa Konupitzky.
Drinking water, surface water and sewage pipes are typically produced in special formwork into which fresh concrete is poured. The quality of the end product depends on the precision of that formwork –one of the areas where Schlüsselbauer excels.
A look inside the assembly hall proves the point: formwork in countless shapes and diameters, tailored to the standards and specifications of countries worldwide.
“High-quality formwork is essential for casting concrete pipes for drinking water, rainwater and wastewater.”
Precision as a core value
“We don’t sell anything we can’t build ourselves,” emphasises Production Manager Stefan Wiesner. “Concrete formwork requires precise bends. It must hold self-compacting concrete in shape during pouring and hardening. Take sewer systems: parts must fit together seamlessly – tiny deviations can have major consequences.”
This is precisely why the manufacturer set out to find a new press brake – not only for precision work, but also for large machine components and special frame parts that demand the highest machine standards. Four years of intensive research and consultation led them to the perfect solution.
The largest LVD press brake in Austria
During this process, Schlüsselbauer worked closely with Matthias Ebner, Sales Manager at Schachermayer, the exclusive distributor of LVD machines in Austria for 40 years. Numerous bending tests confirmed the right direction. In the end, the company chose an Easy-Form-9 press brake from LVD, with a 6-meter working length and 640-ton pressing force.
Guided by the specifications of Mr Schlüsselbauer Senior – “We must choose the highest capacity and the best functionality that truly serve our industry” – the company now operates the largest LVD press brake in Austria.
Equipped with the Easy-Form® Laser (EFL) angle measurement system, the machine automatically compensates for material variations such as sheet thickness, strain hardening and grain direction during bending, without losing production time. The result: maximum bend angle accuracy, less scrap, and a significantly more efficient production process. Re-measuring or re-bending? No longer necessary.
Stefan Wiesner & Matthias Ebner
Complete solutions
Another focus of the company is the automation of entire production processes – a decisive advantage in times of labour shortages. In fully automated systems, the formwork moves autonomously through production. With moulds ranging from 1 to 3 m in diameter, today’s state-of-the-art plants can deliver production outputs of well over 100 components per shift.
“Our solutions are tailor-made installations – designed around the desired level of automation, the customer’s requirements, and the available space. We design and build the machine that fits perfectly,”
It is this comprehensive engineering that sets Schlüsselbauer apart. Stefan Wiesner: “We keep as much as possible in-house, from concept to development, design, manufacturing, assembly, and programming. Our designers, electrical engineers, programmers, and fitters all work under one roof. We support our customers every step of the way, right up to commissioning in their concrete plant.”
Mario Mair (Head of steel construction Schlüsselbauer), Stefan Wiesner (Production Manager Schlüsselbauer), Matthias Ebner (Sales Manager Schachermayer)
International player
Schlüsselbauer employs 300 people, most of them at the Austrian headquarters. The company operates a production site in the Czech Republic and a sales and service branch in Nashville, Tennessee (USA).
The scale is remarkable: not only in the size of the machines - some of them truly gigantic – but also the number of countries they are shipped to. From Europe to the USA to Asia, customers place their trust in machines “Made in Austria.”
“In many cases we have replaced the welded constructions with bent parts.”
Expanding horizons.
For nearly a year, Schlüsselbauer has been operating the LVD press brake, and Mr Wiesner is satisfied: “The machine’s accuracy has fully met our expectations. We manufacture precision formwork, frames and spare parts, and in many cases have replaced the welded constructions with bent parts. Our steel construction department is particularly impressed: the parts fit together much better, making assembly and welding much easier.”
But precision is only part of the story. “The system has boosted our capacity: we can now produce many parts that were not feasible before, including smaller components with sheet thicknesses up to 20 mm. We are constantly discovering new possibilities. Working closely with our design department, we are developing concepts that are easier to implement,” he concludes. “This investment has not only enhanced our precision, but also broadened our horizons.”
The Magic machine is used worldwide to manufacture both rectangular and circular shaft components in various heights
PROFILE
Stefanie Vandemoortele, LVD Company
