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How do intelligent sensors contribute to more efficient and sustainable prefabricated housing construction?

Sensoren, RFID-readers en laserprojectoren versterken de precisie, efficiëntie en flexibiliteit binnen het productieproces van prefab houten woningbouw. Maar hoe werken deze sensoren precies, wat is ervoor nodig om te te implementeren, en levert het rendement op? In dit artikel gaan we in over hoe deze geavanceerde technologieën een cruciale rol spelen in het aanpakken van […]
How do intelligent sensors contribute to more efficient and sustainable prefabricated housing construction?

Sensors, RFID readers and laser projectors enhance precision, efficiency and flexibility within the production process of prefab wooden house construction. But how exactly do these sensors work, what does it take to implement, and does it provide a return on investment?

In this article, we discuss how these advanced technologies play a crucial role in addressing the housing shortage.

Hoe kan er in de prefab tijdens de productie verduurzaamd worden?

Prefabricated construction contributes to sustainability, a key goal within Industry 4.0. Optimized processes reduce material waste, increase energy efficiency and reduce transport movements. This aligns with the circular economy principles central to Industry 4.0.

The combination of RFID readers & the precast industry

RFID technology provides real-time visibility and control over every part of production. The system plays a central role in managing information and streamlining the production process.

  • Tracking of building components: Each element is equipped with an RFID chip, which contains all relevant information, such as design, production status and assembly instructions.
  • Real-time access to data: With a reader, operators scan the RFID chips to recall exactly the information needed at the time, such as the exact placement of pipes and switches. This prevents operators from being overwhelmed by irrelevant information.
  • As-built data: Upon completion of each building component, quality checks and inspections are stored on the RFID chip. This data is essential for certification and record keeping in the future.
Prefab scan

What is required for the implementation of RFID chip in the precast manufacturing process?

Implementing RFID technology in precast manufacturing processes requires a combination of the right hardware, software, organization and strategy. When implemented properly, it offers great benefits, such as more efficient management of construction parts, reduced errors and increased productivity.

  1. Technological infrastructure

    RFID tags: Each precast building component must be equipped with a unique RFID chip. The choice of appropriate tags (e.g., passive, active or semi-active) depends on the environment (e.g., temperature, humidity) and the desired reading distance.

RFID readers: Scanners should be installed at strategic locations in the production hall, such as assembly lines, quality control points and logistics hubs.

Data management software: An integrated software system (e.g., an MES or ERP) is needed to read, process and link RFID tag data to product information such as design drawings, quality documentation and delivery schedules.

Network connection: A stable and secure IT infrastructure for transferring data in real-time is essential, especially if the system is linked to a cloud environment.

  1. Organizational adjustments
  • Process integration: Existing workflows must be modified to seamlessly integrate RFID use into the production process. This may mean adding or automating certain stations or controls.
  • Staff training: Employees should be trained in the use of RFID technology, such as how to place tags, scan them and interpret the data.
  • Quality control: The process must ensure that all chips are correctly placed and functional before the building components move forward in the process.
  1. Standards and protocols
  • Unique identification: RFID chips must conform to standardized protocols (such as EPCglobal) to ensure universal and consistent identification.
  • Interoperability: The RFID system must be compatible with existing software, machines and other technologies, such as laser projectors and sensors.
  1. Logistical requirements
  • Placement of RFID tags: The location of the chip must be chosen carefully. It must not interfere with assembly and must be protected from damage during production, transportation and installation.
  • Tracking and tracing: A system to track each construction component throughout its life cycle - from production to assembly - must be established. This is especially important for ensuring quality and managing warranties.
  1. Financial and strategic planning
  • Cost-benefit analysis: RFID implementation requires an initial investment. It is important to weigh the cost of chips, readers, software and training against the expected benefits, such as improved efficiency and reduced failure costs.
  • Scaling capabilities: The system must be flexible enough to scale with growing production or new precast projects.

Prefabricated solutions from Sensor Partners

Sensor Partners has specialized in non-contact measurement and sensing for 32 years.
Our team bridges the gap between traditional business issues and intelligent sensor solutions. Our technical experience has helped us create solutions with sensors, helping prefabs become more sustainable and optimized.

In addition to supplying sensors, Sensor Partners also supports precast manufacturers with the installation of laser projectors and rangefinders which is essential to maximize durability and efficiency:

Custom installations for prefabricated processes: Sensor Partners configures sensors and places them at critical points within the production process. Think laser or ultrasonic sensors for detecting building parts, distance measurements and precision control during assembly.

  1. Integration with existing systems: Sensor Partners links sensors to existing automation or BIM systems. This ensures that data are seamlessly integrated into processes such as tracking, quality control and energy management.
  2. Workstation optimization: Precast modules often use workstations where building components are assembled. Installing sensors that provide real-time data, such as laser projectors or light displays, increases worker efficiency and safety.
  3. Training and maintenance services: In addition to installation, Sensor Partners can provide training for employees on how to use the sensors and their software, as well as perform periodic maintenance. This helps manufacturers make optimal use of the technology for a long time.

With expertise in sensor technology and installation, Sensor Partners can completely unburden precast manufacturers: from design and selection to implementation and maintenance, while meeting sustainability goals and achieving cost savings. Do you have a specific application in mind that requires additional explanation?

What is the efficiency of sensors in the precast industry?

The use of sensors in the precast industry offers significant benefits, especially in the areas of production, cost savings, quality assurance and personnel requirements. Here are some of the key benefits:

  1. Higher production

Sensors help optimize manufacturing processes by providing real-time data on progress, material usage and machine performance. This enables faster, more accurate production. For example, by using laser projectors for precise part placement and RFID chips for material tracking, factories can operate faster and more efficiently, with less chance of errors and delays. This leads to higher output and shorter lead times for precast construction projects.

  1. Cost reduction

Sensors can provide significant cost savings in several areas:

  • Less material waste: Precise sensor technology, such as laser and distance sensors, allows materials to be cut or assembled exactly the right way, reducing waste.
  • Optimize energy consumption: Smart sensors can monitor energy use and help reduce unnecessary energy consumption, contributing to lower operating costs.
  • Maintenance costs: Predictive maintenance with sensors allows plants to predict and prevent failures, minimizing costly repairs and downtime.
  1. Quality assurance

Sensors increase product quality by improving accuracy and consistency. With sensors, manufacturers can continuously monitor the production process, perform quality control in real-time and detect deviations immediately. This leads to higher product quality and ensures that precast elements meet required standards and specifications without costly rework or revisions.

  1. Less staff required

By using sensors and automation, factories can reduce labor requirements without compromising production capacity or product quality. Sensors can take over repetitive tasks such as measuring distances, checking positions, and monitoring the progress of production parts. This reduces the workload on employees and makes it possible to achieve higher output with fewer personnel, which also saves costs.

Thus, in the precast industry, the integration of sensors leads not only to increased efficiency and cost savings, but also to increased product quality and safe working environments. Continuing technological advances allow these benefits to be continually expanded, enabling precast manufacturers to benefit both economically and environmentally from innovations in sensor technology

Laser projectors: Accuracy in assembly

Laser projectors support factory workers in performing their tasks accurately. This technology provides visual assistance and increases efficiency and precision.

  • Visual Guidance: Lasers project exact positions on the wooden elements. This helps workers correctly position the wood framework, piping, wall outlets and other components, eliminating the need for manual measurements. 
  • Synchronization with tilting: When an element is tilted during assembly, the laser projection automatically rotates with it. This ensures that the projection remains in the correct position regardless of the element's position.
  • Time savings and error reduction: The use of laser projection allows operators to work faster without sacrificing precision. This minimizes errors and increases productivity. It also provides a significant reduction in material loss.

Integrated technology for a streamlined process

The combination of sensors, RFID readers and laser projectors makes the production process of prefab wooden houses more efficient, flexible and accurate. Together, these technologies provide:

  • Precision: Millimeter-accurate machining through sensors and laser projection.
  • Efficiency: Real-time access to relevant data through RFID technology.
  • Flexibility: Dynamic adjustments possible during the production process.
  • Sustainability: Less material loss and a safer working environment for employees

    With the same staff to 50% higher productivity, higher safety, quality and cost savings. 

    This technological approach is not only innovative, but also a key element in the success this prefab wooden house construction, which focuses on customization and high quality.