Sustainability, automation and digitization in the concrete industry 

The precast industry, like many other industries, faces many challenges. From labor shortages to the environmental crisis, the industry is doing its best to stay at the forefront of and lead a sustainable future. 

Sustainability has many meanings. To simplify, a sustainable industry, to achieve a goal, can be said to make careful use of available resources and preserve them for the future. Advancing climate change makes this issue increasingly important and also calls for more energy-efficient building systems and materials. Progress Group also originally sees sustainability as the efficient construction of sustainable buildings, taking into account: 

- A comfortable indoor environment;

- Energy efficient living and building;

- The second life of buildings;

- Affordable building material;

- Innovations to improve ecological footprint;

- Precast concrete elements that can be recycled for 00%.

It is not only the construction material, construction methods and regular innovations that contribute to sustainability, but also the most diverse aspects of execution. Precast concrete elements promote planning quality and, because of the controlled working environment, working conditions are safer. 

Automation is not just robots! 

Automation is so much more than robots replacing humans. The main purpose of automation is to reduce heavy and sometimes even dangerous human labor in order to make production more efficient and safer. WITHOUT completely wiping out human needs. By using specialized machines and computers, production can be achieved without the need for heavy human labor. The goal is an intelligent production facility that uses data for automated production, leaving humans to manage only the machines and eliminating the need to work on the product itself.

Automation in production plants 

The automation of reinforcement production, the production of prestressed concrete elements and the application of complete carousel systems for precast concrete elements lead to less waste, fewer errors, more safety and higher quality in a shorter time. For example, improved machine automation in the production of prestressed concrete elements can be achieved with a concrete distributor with flying trays and automatic ordering of concrete, as well as automatic unloading of concrete into the production machine. While the production machines run automatically, the machine operator - during production - can work on other tasks. A great example is tracing with the plotter, which marks with cutting lines where the cut-outs in a slab are to be made. And that with extreme precision!

Thanks to the plotter, it is possible to work to the nearest millimeter - which cannot be achieved by hand. With this machine, drainage holes for draining water can be drilled, for example. For this, Progress Group offers an automatic solution, so cut-outs can be made by hand or with an Aspirator. The Aspirator is normally operated by an operator, but can also be equipped with an automatic module. Cutting the cured sheets can then again be done fully automatically, making the production flow safer, faster and more accurate. With automation, this results in a cleaner factory, with fewer people in the plant hall, who will also work more safely and efficiently. 

Digitization: unlocking the full potential

Another big advantage is digitalization in construction. In today's fast-paced world, digitization has emerged as a game-changer for the precast industry. Over the years, the integration of advanced technologies such as Building Information Modeling (BIM), cloud-based collaboration platforms and automation tools has revolutionized the way project management, communication and productivity are approached. Advanced tools such as BIM allow precast companies to visualize projects in a virtual environment, enabling better planning, coordination and error detection. This not only streamlines workflow, but also minimizes costly rework and delays. Cloud-based collaboration platforms enable real-time sharing of project information, promoting seamless collaboration between teams, stakeholders and partners. This instant exchange of data and feedback promotes transparency, facilitates quick decision-making and ultimately accelerates project timelines. By embracing these modern technologies, construction companies are unlocking new levels of efficiency, quality and sustainable construction.

The digital transformation of precast concrete production

Prefaco, a very well-known precast plant based in Belgium, has recently undergone a groundbreaking transformation in its operations, thanks to Progress Group's specialized Manufacturing Execution System (MES). Prefaco Oeterbeton, specialized in producing double walls, zero walls and ceiling elements, was looking for a comprehensive solution to improve its production processes. In August 2023, the ebosyc MES system was rolled out at Prefaco Oeterbeton. In doing so, they went beyond a software implementation. Prefaco Oeterbeton also upgraded the welding machine M-system for mats and integrated a formwork robot Form Master and lattice girder machine Versa from Progress Group. In addition, the MES system works seamlessly with a third-party carousel system and the ERP system, creating a fully integrated production environment. Previous manual processes for sending CAD data to machines and estimated scheduling were less efficient and flexible. The now newly acquired flexibility allows Prefaco Oeterbeton to improve its productivity, through features such as pallet allocation and semi-automatic pallet routing, while also enabling critical functions such as quality control and smart manufacturing. Luc Lenaerts, project manager at Prefaco Oeterbeton, says: "The real strength of the system lies in its flexibility and ability to adapt automatically. It is remarkable how seamless the communication between the individual machines is."

In summary, the cooperation between Prefaco Oeterbeton and Progress Group and the adoption of the ebosyc MES system have revolutionized precast concrete production. Lenaerts also pointed to the good cooperation between the Prefaco team and Progress team, which enabled a timely migration. With improved efficiency, adaptability and integration, Prefaco Oeterbeton is well positioned to remain an industry leader and set new standards for quality and innovation in the years to come.