Laser technology has established itself as a revolutionary solution in the prefabricated concrete element manufacturing sector, significantly boosting both efficiency and precision. SL-Laser GmbH, based in Traunreut, has met growing customer demands for faster, more accurate, and cost-effective production processes with its innovative laser systems. These systems are deployed worldwide within the construction industry and prefabricated concrete production, becoming indispensable tools thanks to their ease of use, rapid setup times, and robustness.
At the heart of this technology is a computer-controlled laser system that, combined with specialized software, work plans, and measurement points, projects precise and swift contours onto large or complex mounting surfaces. The ProDirector 7, an advanced laser projection system, enables exact positioning of formworks, embedded components, and reinforcements in the concrete prefabrication industry. It can be installed as a fixed unit or mounted on rails for long-distance travel, offering flexible operation across different production environments.
In its fixed variant, the laser is especially used in continuous circulation plants, where pallets are placed directly beneath the laser. Depending on the selected program, various elements such as formworks, pre-assembled parts, and magnetic lines can be projected at different heights. These heights can be stored in advance or entered manually via the user-friendly ConcretePilot software. The software also allows saving functions on a remote control, further simplifying operation.
The rail system operates similarly, with the laser moving along a predefined path from one position to another. In practice, laser systems have been installed on tracks up to 120 meters long, enabling complete production processes to be planned in CAD. Each time the laser stops at a specific position, all relevant elements for that production step are projected. These elements are placed at different positions, allowing flexible adaptation to specific needs. The system’s software supports all common formats such as DXF, DWG, ULB, and HPGL for projection, and client-specific data formats are tested internally and optimized closely with customers. Moreover, the laser systems integrate seamlessly with standard control systems, facilitating their incorporation into existing production workflows.
A clear example of the versatility and efficiency of laser projection systems is the Stigloher concrete plant in Bad Aibling. Here, a rail system with two mobile laser projectors assists in positioning complex geometries of prefabricated elements. Two ProDirector LR laser projectors, specially designed for long-distance use, were selected for this application. These lasers can operate independently or couple together to project entire large drawings simultaneously, each handling part of the projection. The capability to project millimeter-precise contours for formworks with curved and inclined lines, as well as pre-assembled parts and recesses, at the push of a button has greatly enhanced manufacturing accuracy and speed.
The laser is connected to a PC and controlled via the ConcretePilot software. Calibration in new positions occurs automatically. Data transmission takes place through the guide rail, increasing flexibility and efficiency throughout the production chain.
A standout feature of these laser projection systems is their calibration process. Typically, calibration is performed using four fixed calibration points located near the table or on supports placed close to pallet circulation areas, ensuring precise projection. On tilting tables, the points are secured with support structures or through holes drilled directly into the table. This arrangement ensures that when the table tilts backward, the calibration point remains level with the table surface. This design allows the projection precision to be continuously adjusted, regardless of the set height.
With laser projection technology, the prefabricated concrete industry is making a quantum leap forward—enhancing speed, precision, and cost-efficiency, and paving the way for smarter, more flexible manufacturing processes worldwide.
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