Developing new precast concrete products

Innovations in industrialized construction strengthen your competitive edge!

Discussing all issues with your customers and constantly exchanging ideas with them gives us a clear perception of what the precast concrete market requires.

Being a planning and consulting company, we do not consider replacing staff with machines or automation to be a significant innovation. For us, innovations are things that revolutionize the product or the production process.

Such innovations lead to advantages for our customers in the market and competition.

Development of new precast concrete products

How are these innovations developed?

The ever faster penetration of our environment, including our buildings, with information technology and automation require new buildings and custom solutions that go far beyond automation and mechanical engineering.

Which innovations have been invented by us?

Pallet circulation plant with continuous pallet transport for the production of concrete elements

Christian Prilhofer, CEO at Prilhofer Consulting, invented a method for the production of concrete elements in a pallet circulation system, wherein the pallets move at a slow speed through the individual work areas. The work areas are designed in a way that enables the execution of several production steps on a pallet at the same time.

Advantages of this circulation system

The work areas can thus be designed more concentrated and more optimal and the distances to be covered by material, staff and machines are reduced to a minimum.

A work area of a few meters is sufficient for every production step. The length of the hall can therefore be reduced significantly. Investment for ground, buildings and machines decreases.

The plant capacity can be modified by the continuously adjustable transport speed of the pallet, which makes higher plant performances possible.

Reinforcement element, appliance and procedure for producing a reinforcement element

Another invention by Mr. Prilhofer is a reinforcement element, which is both mesh and lattice girder, produced from single rods and in one machine.

Advantages of this reinforcement element

The innovative reinforcement element according to the invention has the advantage that the lattice girders are already connected to the reinforcement mesh. This has the particular advantage that all subsequent automated processes are extremely simplified and respective costs for personnel and machine technology can be saved.

Infinitely height-adjustable formwork system for the manufacture of precast concrete products

Another invention by Mr. Prilhofer is a formwork system for the production of precast concrete elements, which is individually adaptable to the thickness of the precast concrete elements to be produced, with the formwork profiles being equipped with an adaption mechanism and the front plate, which is the side facing the precast concrete element, being replaceable.

Advantages of this formwork system

The amount of basic shuttering forms can be adapted to the number of pallets in the circulation system because all the necessary precast concrete element thicknesses can be produced with a basic formwork system. It is no longer necessary to store a multitude of formwork profiles with a fixed, unmodifiable height for different precast concrete element thicknesses. The necessary storage area can therefore be reduced to a minimum.

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Reference projects

  • Kerkstoel 2000+ - Precast concrete plant in Belgium

    Kerkstoel 2000+(Belgium)

    Kerkstoel 2000+ is among the most important producers of floors and double walls in Belgium and known for its effective production units. Prilhofer Consulting has already designed two production facilities for Kerkstoel 2000+. For the design of the new production facility Kerkstoel 2000+ was approaching Prilhofer Consulting for the coordination. The new facility must produce all types of walls in a flexible and efficient way.
  • Lauter  -  Lauter - precast concrete plant in Germany


    Lauter Fertigteile is one of the central players in the semi-finished precast elements sector in the Augsburg and surrounding area. For the planning of a new, modern and highly efficient pallet circulation system for slabs, double walls and solid walls, the company has secured the support of the leading industry experts from Prilhofer Consulting.
  • Gamuda (Factory 1) - Modern precast plant in Malaysia

    Gamuda (Factory 1)(Malaysia)

    Gamuda, as one of the most important real estate developer in Malaysia and new entrant into the field of industrialized construction, wanted to have a master planner and partner for the project management. Their aim was to save time and money and get an optimum quality by cooperating with a consultant.
  • Mammut - High capacity pallet carousel system for precast elements in Dubai

    Mammut(United Arab Emirates)

    Construction of a precast plant was started for Mammut Technocrete in Dubai at the beginning of 2005 after comprehensive planning. The factory has three production lines: a semi-automatic circulation system, a special production line fitted with conventional tilting tables and a fully automatic pallet circulation system, which is in a league of it’s own when it comes to size and degree of automation. The overall plant concept was developed and worked out by Christian Prilhofer Consulting in Freilassing.