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Pre-fab manufacturers face the challenge of accurately tracking the usage frequency of formworks during concrete part production. Formworks are critical components used to shape and support concrete during casting, and monitoring their usage is essential for cost optimisation, quality control, and resource management. However, traditional manual tracking methods are often labor-intensive, prone to errors, and lack real-time insights.
Modern precast plants still rely on clipboards, bar-code scans and gut feeling to decide how often a formwork has been poured, stripped and cleaned. Because every cycle is not captured, maintenance planners work with incomplete data, moulds stay in service past their safe life and fatigue-related blow-outs shut down production lines without warning. The gap between perceived and actual usage also distorts depreciation schedules, inflating operating expenses and eroding profit margins.
When auditors, insurers or clients ask for a verifiable usage history, the answer is usually a patchwork of spreadsheets that fails to prove compliance. In a competitive market where every slurry splash counts, this lack of transparency undermines both quality assurance and customer confidence.
Unchecked, the problem spirals: unexpected downtime, emergency refurbishments and replacement moulds eat into capital; meanwhile, staff hours are wasted piecing together manual records that never quite reconcile.
Need clarity on cycle counts?
Follow the Usage Frequency Solution link to see how ConcR closes the information gap.
In many precast plants, demoulding still happens “by the clock.” Operators add generous safety buffers to cover temperature swings, seasonal changes and mix variations, yet those same buffers lock valuable formwork out of service for hours longer than necessary. Fixed schedules ignore the true maturity of each batch, so management faces a painful choice: wait too long and sacrifice capacity, or strip too early and risk micro-cracks, cold joints and costly rework.
Traditional thermocouples offer partial insight, but without continuous strength prediction they cannot reveal hidden hot- and cold-spots that develop during hydration or steam-curing. The result is a production process riddled with blind spots that silently erode throughput. Worse, quality-control logs assembled from scattered paper records struggle to satisfy ISO 9001 or EN 206 auditors, opening the door to non-conformities and claim disputes.
Every lost hour of curing room capacity forces a cascade of delays—from reinforcement scheduling to delivery truck slots—and the financial impact multiplies rapidly across large-volume plants.
Want to remove the blind spots?
Visit the Curing Optimisation Solution page to discover how ConcR brings real-time maturity data to your fingertips.
A single precast yard can sprawl across thousands of square metres, and moulds frequently move between production bays, storage racks, cleaning stations and outbound trucks. Without continuous geo-tracking, crews embark on time-consuming “mould hunts,” delaying pours and pushing overtime costs higher. Misplaced formworks create bottlenecks in staging areas, and when a high-value mould disappears entirely, the financial hit can climb into six-figure territory once replacement, freight and schedule disruption are tallied.
Lacking indoor positioning, GPS alone cannot show whether a mould is in Bay A, Bay B or the blast-cleaning booth; it may even report a location hundreds of metres away on the other side of a concrete wall. That imprecision fuels arguments between logistics teams and external hauliers, while insurers demand a robust chain-of-custody that paper delivery notes seldom provide.
The ripple effect extends beyond the factory gate: late deliveries strain customer relationships, emergency rentals erode margins and inventory managers lose confidence in their own stock counts.
Ready to know every mould’s location?
Head to the Geo-Localisation Solution page and learn how ConcR puts your entire yard on the map.
Find out how our customers have dealt with these challenges
Real-time cycle counts on 680 steel formworks boosted mould life by 22 % and paid for itself in 26 weeks.
Maturity-based stripping lifted throughput 14 %, cut steam energy 12 % and slashed rejects 60 %.
Live GPS + UWB tracking eliminated lost moulds, halved retrieval time and avoided AUD 0.8 M in replacement costs.
