Sign gantries made by Max Bögl

28.04.2019

The Federal Transport Infrastructure Plan 2030 with a total volume of almost 270 billion euros includes investments in the maintenance and repair of the transport infrastructure as well as around 1,000 expansion and new construction projects. As part of these projects, Max Bögl produces traffic sign bridges, so-called gantries, as supporting systems for trailblazing signage or variable message signs. On motorways and multi-lane inner-city roads, intelligent traffic control systems ensure greater safety.

Sign gantries made by Max Bögl

 

More road traffic safety

In the course of the future development of traffic control measures on Germany's trunk roads, Max Bögl has been able to gain one of Germany's leading companies in the field of traffic engineering as a cooperation partner. In future, the components required to equip the gantries, including the associated control technology, will be supplied by Bremicker Verkehrstechnik GmbH based in Weilheim i.OB.

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Photo: Reinhard Mederer

 

The traffic sign bridges manufactured at the headquarters of the Max Bögl group of companies in Sengenthal consist of transom/stick constructions as hollow steel boxes or, in the case of large spans, as truss constructions. They are fastened to foundations on the side of the roadway and, if required, equipped with an impact base. Steel is the perfect material that makes stable yet filigree structures possible and is characterised by its low weight, high strength and durability. With a span width of up to 58 metres, which corresponds to a width of about six lanes, the gantries equipped with intelligent sensor technology can be configured as required with various additional equipment such as maintenance footbridges, climbing aids or cable entries.

 

Quality based manufacturing process

After the flame-cutting of the necessary sheets and the bending of the supporting profiles, the individual components are assembled at specially designed work stations. State-of-the-art welding equipment joins the steel components together in compliance with strict quality regulations. The contact screw joints of the joints between bridge transoms and bridge supports required for the overall assembly are machined on high-precision drilling/milling centres with tolerances in the 100th millimetre range. This guarantees a defined force transmission, especially in the dynamically stressed corner area of the gantry sign.

 


Photo: Reinhard Mederer

 

Optimum corrosion protection

After the steel components have been given a thermal zinc coating at around 450 °C, the individual components are additionally coated with up to three layers of anti-corrosion paint in a complex coating process. This protects the steel from aggressive influences in later applications on motorways and federal highways. All processes in production, hot-dip galvanizing, painting and pre-assembly are continuously supervised by internal quality assurance staff. Before delivery, external acceptance officers of the respective customer ensure that the steel components and associated components are executed in accordance with the contract. Only then is the release for delivery given.

 


Photo: Reinhard Mederer

 

Implemented lean processes

The methods for the efficient design of the entire value chain could be successfully applied and optimally coordinated on these systematized buildings. From prefabrication and assembly to the welding stations: The specified times from the calculation could be effectively implemented by means of a specified cycle production of the individual workstations. By means of a clearly defined design of the storage area, taking into account a defined material flow, the individual workstations could be optimally set up. The daily communication of improvement potentials and the rapid implementation of corresponding measures the very next day result in continuous process optimization.

 

"Through the targeted application of lean methods, we were able to achieve significant improvements in the manufacture of the gantries. The reduction of intermediate stocks and throughput times as well as the optimisation of work processes not only represent added value for our company, but also for our customers in particular".
Matthias Lang, hall manager

 

Short blocking and installation times

The pre-assembly of the complete substructure with sign and wiring as well as the test run of the LED signs and prism turners are also carried out "ready to plug in" in the company's own assembly hall. The trial assembly of the complete sign on the previously produced steel support structure ensures a smooth and short shut-off period of a maximum of 15 minutes on site. In addition, the customer receives a comprehensive delivery service with fully equipped large components and all other assembly components - right up to the repair kit for repairing possible assembly damage to the corrosion protection. The components are individually pre-picked and packed and delivered separately for each location. This reduces assembly time on site to a minimum.

Just-in-time logistics

Since the construction sites to be supplied are mostly located on busy traffic routes, the components are delivered just in time - carefully planned by our own transport and logistics department. This department also carries out the necessary calculations of the main focus of the entire vehicle, the route inspection, the obtaining of transport permits as well as the preliminary acceptance of the entire vehicle with the police. The synchronisation of the escort vehicles in order to bring the up to 37 meter long components safely to the installation site is also part of Max Bögl's service package.

 


Photo: Reinhard Mederer

 

Continuous project planning using configurator

However, the group of companies thinks one step further. Using a 3D model, which is created with simple basic data such as bridge span and shield area to be applied, it should be possible in future to submit a binding offer to the customer in advance by means of a configurator and to make the execution planning available in the event of an order. At the same time, the production data for controlling the flame and welding machines are to be generated from the model. This enables a continuous project planning from the determination of requirements to the assembly and operation of the gantries.

 

benefits for the customer

  • All from one source: planning, pre-assembly in the factory, quality assurance, transport and final assembly
  • supplying the construction site with all necessary components
  • Complete final acceptance at the plant, thus minimizing errors and cost savings on the construction site
  • Predictable assembly dates due to just-in-time delivery of components
  • Short pauses between stops and installation times
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