Improving quality in precast concrete production

Beyond Prefab, a leading Amsterdam-based precast concrete producer, has a state-of-the-art carousel plant for the production of solid walls and has successfully integrated VISION.IMAGE, an advanced quality control system, into its production processes. This strategic investment reflects the company's commitment to providing high-quality products.

The turning point came when Voorbij Prefab expanded its carousel plant. “We wanted 100% quality, without post-processing on site or after pouring,” explains Hans Both, IT manager at Voorbij Prefab. “When the opportunity arose with VISION.IMAGE to implement a camera-based quality control system, we decided to take that step.”

Sustainability as a driving force

Sustainability and quality go hand in hand at Voorbij Prefab. All the standard concrete the company produces already meets the CO2 performance levels tailored to the Paris Climate Agreement targets for 2030 as standard. With Impakt Concrete - a solution that is already in practice - Beyond Prefab goes even one step further and meets the 2050 CO2 values. To achieve this in a consistent and flawless manner, Voorbij Prefab is consciously working with innovative technology leaders such as Progress. The implementation of the VISION.IMAGE system enables error-free production, eliminates rework and waste, and directly supports a more sustainable production process. In this way, digital innovation, product quality and sustainability come together seamlessly - and form the basis for future-proof precast concrete.

VISION.IMAGE: real-time quality control

The VISION.IMAGE system, developed and provided by Progress Software Development, detects and controls the correct placement of inserts in precast concrete elements. It operates on three levels:

- Real-time detection of inserts: the system immediately indicates whether all required inserts are present on the production line. “You immediately see if something is missing - and that can then be fixed before pouring,” Alexander van Tintelen says,
Director at Beyond Prefab.

- Position accuracy: right now, the system is already delivering great results. Voorbij Prefab is working closely with Progress to further refine calibration and increase positional accuracy.

- AI-powered automation: two AI modules have been ordered to enable fully automated detection. When these are implemented, the system will automatically stop the pallet if errors are detected, allowing employees to immediately fix these problems.

In addition, VISION.IMAGE is complemented by EBOS®, Progress Software Development's Manufacturing Execution System (MES) for carousel plants. EBOS® controls the formwork robot, regulates production planning and optimizes plant output, making it the digital backbone of daily production at Voorbij Prefab.

Operating system migration

Perhaps even more important was the ongoing modernization of the carousel plant, which currently involves a migration of the control system from obsolete Siemens technology (2004) to the Beckhoff control system, along with the necessary modifications in EBOS®. “We discussed this for many years,” Both looks back. “Progress Group switched to Beckhoff as the standard platform after 2004. We were faced with a choice: Replace Siemens components with newer Siemens equipment or migrate completely to Beckhoff.” The deciding factor was future-proofing. “If we stayed with Siemens, we would miss future developments and lose the technical support from Progress.”

The migration was done in four to five weeks as a comprehensive ‘Big Bang’ implementation. “The Siemens components were at the end of their useful life anyway - they are 20 years old,” Both explains. “Beckhoff offers new possibilities, especially in the area of safety. It was the right decision.” The move follows a long history of continuous improvements: the plant was already modernized with several machines in 2015. In addition, last summer it was further equipped with accessories for pallet transport, transverse movements and two lifting devices. By the end of 2025, the plant was further modernized with fully automated packaging machines, including storage and internal transport.

Partnership and cooperation

The relationship between Beyond Precast and Progress Group is an example of a strategic partnership in the precast concrete industry. Both organizations recognize that continued success requires ongoing dialogue and a shared vision. “You have to maintain a good relationship to move forward,” Both emphasizes. “It's not just about addressing issues, but regular conversations about what's new, what's possible and what we want to achieve in the future.” Beyond Prefab initially felt like a ’test case’ during the implementation of VISION.IMAGE, as several features still needed to be refined over a six-month period. However, the company remained patient and willing to cooperate, recognizing that integration simply takes time.

Current focus

The implementation of the two AI modules ordered will be the next milestone. Once properly calibrated, these modules will enable autonomous insert detection and automatic pallet stop functionality, which will take quality control to the highest level.

Lessons from digital transformation

Beyond Prefab's investment in the VISION.IMAGE, EBOS® and carousel plant modernization provides valuable lessons for precast manufacturers considering similar investments: embrace innovation, maintain strong relationships, be patient with integration timelines and never lose sight of the ultimate goal: to deliver 100% quality to customers, every time. “We are always open to new developments,” concludes Both. “If we find something we believe in, we commit to it - even if the path is not entirely clear at first. That's how you encourage progress.”