The benefits of precast concrete manufacturing processes include cost efficiencies, quicker site delivery and an easy installation of a product that has been seamlessly manufactured to the highest standard. It is the smart way to build high quality buildings that are safe and affordable.
Applications for precast products are numerous: from public, residential and commercial development wall, floor and roof panels, car park construction and building facades. The potential for precast slab applications is vast. Elematic, in particular, is a world leader in the development of technologies specifically for the manufacture of precast flooring. It holds over 260 valid patents and is the largest investor into research and development in this sector globally.
Getting Started
Once the idea of establishing a precast concrete plant has emerged, a pre-study is the next step to answer questions such as “What is the right time to contact the technology supplier and request a quotation?”.
“The earlier our precast experts are involved in the process, the better. Based on their extensive experience in designing precast production plants and the end use of the products, they know what is crucial when pre-planning the plant and machinery. They can ask the right questions and find the most suitable solutions says Leena Raukola, Department Manager of Sales Support at Elematic.
“When our team is involved in the process from the start, we can make sure that the solution really responds to the specific requirement.”
Quotations for various needs
Construction companies, for example, often have a clear idea of what they need. They may plan to acquire an operating precast production plant, or want to set up a new plant to expand operations from cast-in-situ to precast element manufacturing. “Some are looking for new business opportunities having recognised the potential in precast production and want to invest in it,” Raukola says. “They are getting into the concrete business and need more guidance. This is where our expertise can assist through knowledge sharing. It is our objective to ensure that all our customers receive a tailored, relevant and feasible quotation”.
Defining present and future needs
Define what types of product you intend to manufacture – precast wall elements, floors, piles, or Acotec partition walls? Will the focus be on one specific end product or will the plant provide a wider selection? These factors will affect the optimal factory layout, machinery, and floor area needed.
“For companies starting up, it is wise to think about possible needs for capacity expansion later on. This enables future plans to be included in the initial factory layout,” Raukola says. “When the need for higher volume capacity emerges, the machinery can be updated and more production lines can be added quickly and efficiently. If demand happens to decrease, production can be scaled accordingly.”
Local regulations and conditions
Knowing local laws, regulations, fees, documents and processes is critical to precast production plants as they may impact the end use of the product, the construction processes, or environmental issues. “Our specialists can help with calculations of different environmental impacts such as noise or dust. We also offer facilities for wastewater management,” says Raukola.
Three levels of scale
Elematic’s precast concrete plants and products are divided into three levels: SEMI, PRO, and EDGE. This division helps to define the right scale and technology for the quotation. It also gives a common starting point for negotiations in terms of automation, personnel, and capacity.
“The SEMI level is intended for easy start-up of precast production with low investment and automation levels. It requires more personnel than the PRO and EDGE levels. PRO is designed for large-capacity production with a wider product selection and some automation. EDGE is the most advanced level available, with high automation and capacity. All are designed to deliver the lowest operational costs and high-quality end products, no matter what the technology level,” describes Raukola.
Expertise in the process
If there is a need for a new plant, a thorough process leads to a successful outcome.
“Our team often starts with factory layout plans, moving on to the factory details, specific solutions and machinery. The Karkas Monolit factory project in Russia was a good example of a well-executed process,” Raukola concluded.
