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Our Technology
Revo IBS has one of the most modern production plants
for precast concrete elements in the world.
The innovative technology comes from Ebawe Anlagentechnik - Progress Group GmbH.
The new plant is highly automated and equipped with clever, sophisticated machine technology. Eder thus produces double walls with and without insulation as well as precast slabs with insitu topping.
This degree of automation has a major impact on the productivity of the plant. Within 10 days a workforce of 60 persons is able to produce precast concrete elements for 48 four-room dwellings. On traditional construction sites three to four times the number of employees and twice as much time would be required.
The precast plant has significantly expanded our product range, allowing us to produce double walls for the first time.
Its high level of automation has greatly improved product quality and accelerated production, enabling us to quadruple our capacity.
Fully automated shuttering process
The production cycle begins with a pallet entering the automated area, where the deshuttering robot removes and transports shuttering elements for cleaning and storage. After the pallet passes through the cleaner and concrete residues are processed, a release agent is automatically applied only to areas where concrete will be placed.
The "FormMaster" robot then places magnets for outlets, positions the shuttering elements based on CAD-CAM specs, and uses an integrated plotter to mark contours and embedded part positions. The Infinity Notch-Free system handles the loading of 60 pallets with edge shuttering.
Automated reinforcement station
The M-System BlueMesh welding machine supplies reinforcement wire mesh to the pallet carousel plant efficiently, with minimal space and energy use. It includes an automated bending system for lattice girder floors, allowing right-angle bending of rebars in both directions and for walls. Customized bending is also possible. A magnet crossbeam transfers finished mesh to the pallets automatically, and non-automated inserts are handled by a stacker lift truck. For insulated double walls, Gdansk is the first to implement fully automated third-layer mesh insertion without production interruption.
The VGA Versa lattice girder welding machine ensures high-quality, cost-effective production of reinforcement elements, allowing just-in-time manufacturing to reduce storage costs and waste. It features automated height adjustment and wire-diameter changes, with robots handling the final insertion.
Integrated carousel and master computer technology
On the first level, pallets with reinforcement pass through a laser projection system for quality control, and a camera documents each pallet, storing the images in the Ebos master control system.
After concrete is placed, we use two compaction systems: a low-frequency vibration unit for lattice girder floors and a dynamic unit for heavy loads or double walls. Traditional walls are smoothed using a unit with an external vibrator, while lattice girder floors pass through a roughening unit.
A washing carriage cleans the concrete spreader and recycles the water back to the mixing plant.
An automated storage unit moves freshly concreted elements into a pallet rack for curing. Lattice girder floor slabs are removed, while double walls undergo second-layer production and assembly via a turning unit. The hardened double walls are positioned vertically using a tilting device and removed by crane.
The system manages work planning, production, and process analysis in the new plant. Developed by Progress Software Development, it integrates automated pallet assignment and printing of work sheets, labels, and reports, ensuring a seamless and user-friendly system.
With sophisticated logistics to a perfect plant
Ournew production plant is highly automated, requiring few operators and delivering a fast, high-output process. The facility is designed with strict process separation, ensuring independent material flow and product handling. This allows for simultaneous production of reinforcement mesh for external use and special products without disrupting operations.
"The planning was complex, but the result is a perfect plant," praising the smooth collaboration during layout development and installation.
The high-quality precast elements produced here are primarily used in residential projects across the world. The fully automated Revo IBS plant has earned us a strong reputation for quality and precision.
We provide a holistic, natural, and simplified way of building for those who are sick of the old way of doing things.
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