Precast concrete has existed for over a century; therefore, it is not a new concept. The first known large-scale use dates back to the early 20th century. In that respect, it is a traditional method. Nevertheless, many now consider it a Modern Method of Construction. But is that correct?

There is considerable discussion surrounding digital design, BIM integration, factory automation, robotics, AI, and DfMA, among other topics. It seems that we are currently undergoing a digital revolution in precast concrete manufacturing. However, the reality appears to be quite different.

In many cases, digital design has a minimal impact on the manufacturing process. Fabrication drawings are created using advanced tools, yet casting technology has remained largely unchanged since its inception years ago. Indeed, while the method of producing fabrication drawings has evolved significantly, this serves merely as a means to convey information to the factory floor. We cannot construct houses using drawings, even if they are produced with cutting-edge technology.

The same applies to BIM. BIM integration affects the design process; however, it typically has a minimal impact on what happens on the factory floor.

Factory automation and robotics? This is more of an exception than a common practice. Typically, the only sign of automation is a bar-bending machine, which requires manual input as it lacks a connection to design software.

AI? It does not exist in precast construction (yet). It’s merely another buzzword. If it has been implemented anywhere, it is likely more experimental than a fully functional tool. However, it presents well in marketing materials.

DfMA is largely absent in the precast industry. There is no systematic approach, with a lack of standardisation, modularisation, or reuse. Most precast elements are designed on a project-by-project basis, leading to bespoke moulds, unique connections, and inefficient production. Engineers and architects often design in isolation from the realities of factory production. The result? Elements that are difficult, time-consuming, or costly to manufacture and assemble. In many projects, precasters are brought in late, after the structural design has been finalised. This leaves no room for optimisation based on what is easiest or most cost-effective to manufacture and assemble.

Despite claiming to embrace digital transformation, the precast industry remains labour-intensive and heavily reliant on manual work, with minimal or no automation. Even in the digital aspect of the business, many companies utilise the latest design tools, yet production continues to be planned and controlled with Excel spreadsheets, lacking an integrated management system. The precast industry largely remains entrenched in a project-based, reactive model.

What are your thoughts on this subject?