Solving precast challenges with Elematic’s preventive and proactive services 

The global precast construction market is constantly growing due to precast’s unparalleled durability, structural strength, fire resistance, thermal mass, and usability in all climates. Precast elements are produced in precast plants; however, running one effectively is no simple task. Highly controlled production process with advanced technology, precision and skilled workforce is needed to produce every single wall panel, floor slab, staircase etc.  

Through discussions with precasters we have noticed a recurring pattern in the challenges faced by precasters. These typical challenges are mentioned:  

• Downtime: Machinery downtime causes costly losses in production. 

• Productivity: Limited automation and expertise slow down improvements. 

• Workforce & competence: High staff turnover affects productivity and safety.  

• Maintenance costs: Aging equipment increases expenses and lowers quality.  

• Curing time: Green concrete requires longer curing or expensive additives.  

• Quality: Achieving the right concrete mix and process conditions is crucial.  

• Traceability: Meeting quality and sustainability requirements requires better material tracking.  

• Visibility: Poor planning and monitoring lead to inefficiencies and material loss.  

All the challenges above cause significant revue losses. For example, you loose 16,200 € in revenue every day if one extruder is not operational while still incurring operational costs. Also, incurred extra cost of one millimeter extra concrete layer due to suboptimal machine settings can add up to 41,400 €/year. 

At every precast plant more than one person should know how to safely operate the machines, how to use their operating systems and how to maintain them. For example, how to charge batteries, check sensors to avoid tripping, clean photocell sensors and mirrors, wash the equipment, and maintain extruder nozzle and saw vacuum units, and modifier and plotter inkjet systems.  

When there are changes in staff there are changes in know-how. A lot of information leaves the plant, and training is needed for the new mechanics or people responsible for maintenance. 

To solve the challenge, we offer three types of training services: digital training library, e-learning program and in-depth training programs for you to make sure that the right competence is always available at your precast plant.  

• Digital training library: 38 videos on operations and maintenance of multiple machines for fast onboarding and refreshing knowledge.  

• E-learning program: Program for strengthening and tracking competence development and ensuring competence on the production floor, with Elematic’s approval of training competence.  

• Training programs: Ensuring in-depth practical knowledge through classroom and hands-on training. 

Elematic training packages focus on the best practices and safe procedures to operate and maintain the machines. They are always tailored to the needs of specific precast plants and their production. Remember that operator training is always an investment in your precast plant and its efficiency. 

There are two options for tackling precast production challenges: contacting us when unforeseeable factory downtime occurs and the service agreement. Through the first production challenges are solved as they arise. On the contrary, service agreement is a cost-efficient partnership that results in the highest uptime and productivity, achieved through proactive support and quick responses. Here the focus is on preventive maintenance and production improvement before any challenges arise – and if challenges still occur, we try to solve them as soon as possible.  

The service agreement, designed to meet the needs and challenges of precasters, is the most efficient way to utilize Elematic’s global expertise for: 

• Reducing downtime by minimizing unplanned service needs. 

• Cost savings by preventing costly emergency repairs and extending machine lifespan.  

• Expert support through highly skilled experts enabling preventive maintenance and technical support. 

• Increased equipment efficiency resulting in higher output and lover energy consumption. 

Our digital services offer visibility, uptime, productivity – and everything you need for comprehensive maintenance management and planning. Through the system you can access your machine and production data anytime and anywhere, plan maintenance, manage costs, and secure a high level of uptime.  

Depending on your needs, we can manage single machines or connect all your equipment, regardless of the provider, to our maintenance management software, which includes fleet and maintenance management.  

With Elematic service agreement, you gain a trusted partner committed to improving your operations and delivering expert support throughout the entire life cycle of your precast plant.​ No matter the challenge, we are with you every step of the way. Let’s start our journey together!