Our technology
Weinmann Haus’ prefabricated house, a technology somewhat different from the exact concept of a lightweight house, is based on a computer-controlled system from Weinmann, the world’s largest manufacturer of CNC-controlled machining units: a CNC machining centre, construction tables, a multi-platform element manufacturing bridge and a prefabricated element warehouse all in one assembly line.
With this assembly line, we are the only plant in Hungary, both in terms of quality and production capacity.
The walls are slabs, made in halls, in full height and length, in all weather conditions, with external internal thermal insulation and, in some cases, with windows and doors. The elements are delivered to the prepared base in a separate vehicle and assembled there at least in a semi-finished state. It is usually timber-framed and lightweight, but can also be made of brick. In Europe, the prefabricated, large-panel wall panel is typically used, as is the case at Weinmann Haus.
The term lightweight house is also used to refer to prefabricated houses produced in a factory and to frame houses assembled on site. Today it is increasingly used to distinguish site-built houses where 1 square metre of external wall does not exceed 300 kilograms.
As a result of precision engineering and continuous in-production control, the elements produced on computer-controlled Weinmann production lines are characterised by a high degree of dimensional accuracy. The processes of this large-panel, long-established and proven production technology in Western Europe are not affected by weather conditions, so the construction time, including on-site work, is extremely short.
The prefabricated house technology used by Weinmann Haus allows us to complete a 100 m2 building in 2 weeks, by which we mean that the external and internal walls are in place, the slab structure is in place, the roof is finished and the chosen cladding is on top of the roof. Our wall construction allows the construction of buildings up to 4 storeys high.
Why Weinmann Haus?
Our expertise, enthusiasm and customer-oriented approach ensure that the entire design and construction process at Weinmann Haus is predictable and transparent. Innovative prefabricated housing technology with a unique assembly line.
Our manufacturing process
In all cases, production is preceded by a production planning phase to ensure a fully automated technological process. Once the final construction plan has been approved, the engineering department will provide the factory with the necessary documentation and a kick-off meeting to provide information on the building’s production. This package contains the cutting lists, assembly and covering drawings for walls and slabs, loading, surface treatment and packing lists.
The process starts on the WBZ 160 Power six, where the machine automatically measures all the pieces to be machined, avoiding dimensional problems during assembly. The machine operator also carries out a visual quality check to eliminate the use of any twisted materials. The structural basis for the walls, slabs and roof elements is CE-certified KVH-beam from Austria: a longitudinally laminated, kiln-dried, pine-based structural timber. It contains no chemicals, is pest-free and provides a durable shape and stability.
The cutting machine starts the machining process by cutting the beams to size, which are always accurate to the millimetre. These can be vertical and oblique cuts, which are fast and dynamic. There is no risk of displacement because the material is guided by the machine at several points.
Drilling and milling tools of various cross-sections produce the holes and notches specified in the production design, making assembly in the factory and on site both precise and fast.
A wide range of machining options are available. No set-up times are required, as the necessary tools are already in the tool changer and are automatically selected according to the machining operation.
The next station is the structure assembly tables, where, on the basis of the assembly drawing mentioned above, the colleagues assemble the structure of the walls and slabs at the points defined in the software, fix them with Rothoblaas fasteners, check the accuracy of the openings, the diagonal, or provide them with wall support straps or lifting screws, from where the elements are moved by crane. Importantly, quality control is already documented in written form on the production control sheet, which accompanies the whole process. The finished elements are labelled and transported on trolleys to the next station, where the complete wall structure is assembled.
Using a crane, the structures are placed on the table of the WMS 120 Optimat multibridge and secured by pneumatic clamping. On the basis of the covering drawing, our staff will fit the building boards (OSB, high-strength gypsum fibre, plasterboard) according to the customer’s requirements using Schmalz Jumbo Ergo vacuum lifters. The vapour barrier film and any other necessary installation materials are installed.
The building boards are fixed to the timber frame structure by high-speed stapling according to a preset stapling pattern. Mechanical installation openings are easy to dismantle on site and can be closed again when the work is finished thanks to the bolting.
The positions of the hatches and electrical outlets are automatically prepared on the basis of the production plan, accurate to the millimetre. The panel connections will also be perfect.
CNC technology ensures consistently high precision, which provides a wide range of processing options and automatic, rapid tool change for different machining operations.
Once the inside is finished, the structure is turned over using the WTZ 110/12L Optimat & WTW 120/12W/R Optimat butterfly table. Next, the intermediate insulation is applied using an insulating filling technology integrated into the structure, a so-called blown-in cellulose insulation that is guaranteed to be leak-proof. It is also possible to order our structures with rock wool and wood wool insulation.
In this phase, we place the boxes for the high and low current fittings and the cable ducts with the required cross-section. This can radically reduce the time needed for on-site installation.
Once the walls are finished, they are placed on trolleys and transported to the wall storage area according to a loading plan. If we include windows and shading elements, we will install them under operating conditions, if this is not included in our commitment, we will make the building sealable and protected with OSB boards from the first moment of assembly on site.
If our customers require it, we can finish our exposed wood elements in the colour of their choice under factory conditions, using our materials for both interior and exterior use. Before loading, we apply a waterproofing layer to our walls, which is a bituminous mixture applied over a high-density polyethylene layer, without the need for a flame.
The implementation process
- Checking the access and crane accessibility of the construction site
- Base body size check
- Leveling and levelling of the receiving level before installation with special levelling plates
- The completed wall, roof and slab elements are loaded onto a truck according to the loading and assembly plan and delivered to the construction site, where they are assembled with a crane on the prepared reception level. We assemble and install the walls, build the slab, lath and foil the roof structure, then the building is ready for construction. It only takes a few days.
- Each structural element and wall panel is assembled using a software-defined point and method, using high-quality Rothoblaas fasteners.
- After the construction of the house structure, the roof is covered with the roof cladding, which can be tile, sheet or tile-roofed, tin roofing is installed, and the external thermal insulation and surface finishing is carried out, in addition to the external windows. This is how we achieve the state of being ready from the outside.
- Once the exterior is finished, the finishing work is carried out in a similar way to traditional construction technology. The high degree of preparation (breakthroughs, protective pipes, fitting boxes in the walls) means that we are moving faster than usual. This phase includes the electrical installation, the mechanical installation, the floor construction, the painting, the hot and cold tiling and finally the installation of the interior doors.
A few months after the works have started, our customers can already take possession of their new energy-efficient, modern home. - Once all the construction and technical work is completed, the handover takes place, during which the completed residential building is handed over to the client, all the occupancy documents are completed and the house is taken into possession.
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