The 7 steps to concrete innovation
We are often presented with designs that require the production of many different prefabricated components. In creating these elements, the architectural specs like color, constructive strength and shape, are leading. To go from a technical drawing on paper to an actual product, we developed a 7-step process that brings designs to life in a smart, innovative, and sustainable way.
At the start of every project, we break down the design into components. We take a closer look at geometrical shapes, take structural requirements into account, and determine how many elements will be needed and which concrete mix design we will use.
After mapping the total scope of a project, we continue to design unique (patented) moulds. A team of professionals works on the best way to flexibly mould our concrete into any shape needed. We do so in a sustainable manner, with flexible moulds and the recycling of wooden frames.
Before starting the manufacturing of components, we design the production line and determine the production flow. Successive steps are charted and a timeline is created that includes all steps from manufacturing to final completion.
Depending on specific requirements, two different moulds are created: flexible moulds that shape concrete as it hardens and solid moulds that are milled into a variety of shapes. We re-use a solid mould that is optimized to produce as much elements as needed.
Producing elements is a precise task. The complex nature of this part of the process calls for a thought-out plan. Guided by our extensive engineering insights, this is the phase in which we actually create the geometrical shapes and high-quality concrete elements.
Finally, concrete elements are finished. We remove imperfections, level-off any unevenness, roughen the concrete and coat all the elements. If any small modifications need to be made, we do so before preparing the components for transport.
Packaging & on-site delivery
All components are packaged in a secure and sustainable way. We use wooden boxes to transport elements to their final destination. As this is often abroad, we are experienced in finding the right solution for transport by road or sea.