Leading precast technology supplier Elematic has introduced a new automatic Modifier E9 for hollow-core slab production and a WallMES system for the optimization of precast wall panel production which covers automatic production planning, work follow-up and quality control operations.

Elematic Modifier E9

The new automatic Modifier is designed to save concrete with automation and accuracy during precast hollow-core slab production. The new machine offers not only accurate, fast and flexible marking and digging of cutting lines and openings but also significantly reduces concrete consumption in precast plants.

Elematic Modifier E9-1200m is used for digging openings and recesses and drilling water holes on fresh concrete slabs on a hollow core production line. The machine can also plot cutting lines, openings and text. Though designed for automatic operation, it can also be operated in semi-automatic and manual mode.

Elematic Extruder Modified

Fully automatic concrete recycling: Modifier E9 features efficient concrete recycling, enabled by not using any water in the digging process, which means that the concrete removed from openings can be recycled back to the extruder in the hollow-core slab production process. The Modifier thus forms an efficient working couple with the new Elematic Extruder E9, the smart recycling system of which can efficiently feed used concrete back to the production process. Slab quality is ensured by mixing the used concrete gradually with fresh concrete as well as with a time limit. The used concrete will not be fed back to the process if it is older than a factory specific preset time value. Together, these machines will increase efficiency and sustainability of hollow-core slab production.

Concrete consumption with Modifier E9 is further reduced by an advanced digging mechanism that ensures minimum amount of concrete left on the bed.

Fast, accurate, intelligent: Modifier E9 saves considerable time by eliminating the need for manual marking of cutting lines or making openings for lifting loop installations and through holes. The machine uses wireless technology to transfer bed plans to its FloorMES machine control system, and it can take the plans directly from BIM systems. Location information is acquired from the laser positioning system. The laser uses a mirror at the end of the bed to measure distance. Reducing the need for manual work improves production efficiency, eliminates mistakes, and improves safety on the shop floor.

Plant Control Wall

Advanced built-in safety: Like all Elematic machinery, safety features are built-in. The Modifier E9 is fitted with a safety buffer on both ends, including light sensors, which protect the area in the middle of the buffers. In addition, there are ultrasonic sensors that add to safety, and also make it possible to pause the operation when getting close to the extruder (for example) and operation can be resumed when the obstacle moves away.

Elematic WallMES For Plant Control

Elematic, as part of its digital Plant Control solution for precast plants, has introduced manufacturing execution system WallMES for optimization of precast wall panel production. The system covers automatic production planning, work follow-up, and quality control operations. Furthermore, WallMES can take in panel design information directly from BIM systems.

Today, precast plants often lack real time connections between the different work processes. Thus, major improvements in production efficiency and profitability can be achieved by process digitization. The advanced Elematic Plant Control solution is designed for precast production's specific needs: The plant can manage, control and optimize the whole production process as well as individual automatic machines with the system. Plant Control can also discuss with BIM systems such as Tekla Structures.

Optimized wall panel production: WallMES optimizes precast wall panel production. It offers automatic planning, work follow-up and quality control functions for precast wall production plants. It provides the factory with table-specific real-time production progress data with comparison to actual work times versus estimates and waiting times, production efficiency figures and work hour estimates, advanced quality control, easy KPI follow-up with automatic dashboard and customizable reports. The system stores all production history data automatically. The WallMES planning helps factory to balance work plans and available resources per work phase to get smooth and continuous daily work flow. It is also easy to take focused quality improvement actions by combining quality issues, hours required for corrections and work processes where issues have occurred.

Freedom with individual modules: The design philosophy of Plant Control – including WallMES - both functionally and visually, focuses on delivering a great user experience. The system gives the precast plants freedom to choose a path and pace of digitizing their operations. It consists of independent modules that make it easy to proceed step by step, module by module, without any big initial investment.

Furthermore, WallMES – and the whole Plant Control system - feature an easy-to-use visual user interface with a drag and drop function and clear icons and buttons that guide the user through different operations. The system is both easy to learn and simple to use.
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