18,000 m² per Week at Peru’s First Automated Precast Plant

“We appreciate RIB’s innovative software, which is key to the optimization of our operations at Beton Decken. The implementation was crucial to ensure maximum efficiency. We are excited to continue building new projects together.” Ing. Fernando Garbin Turpaud, Operations Manager

Peru-based precast manufacturer, Beton Decken, produces floor slabs, double walls and stair elements designed specifically for earthquake‑prone regions. With a strong focus on quality, safety and efficiency, Beton Decken set out to transform residential construction in South America.

To make it happen, they teamed up with RIB Software for its process and control expertise. By combining digital planning, an open software ecosystem and integrated production know-how, the team built a seamless workflow, from design to manufacturing, that boosts both efficiency and quality.

The first fully digital circulation plant in Peru

Beton Decken ambitiously undertook the immense task of commissioning the first Peruvian fully digital circulation plant within just a few months. The existing manual production was inefficient, error‑prone and posed safety risks. To scale capacity, reduce costs and gain control of processes, the company needed a solution that enabled digital planning, hybrid machine integration and real‑time quality assurance.

A system that adapts to the customer

Beton Decken chose RIB One Prefab with MES and Automation for one key reason: flexibility. The system could integrate both imported used machines and new equipment. That adaptability proved crucial, it let the team reuse existing assets while still creating a fully digital, tightly controlled production environment.

Together with RIB, Beton Decken co-engineered a tailored plant concept that brings circulation control, logistics, robot integration, and laser projection together in a single system. The rollout took place in phases, supported by remote training, on-site coaching and close collaboration between planning, control, and production. The result is a precise, digital, and cost-efficient factory that performs reliably, even under challenging conditions.

Measurable improvements

Within eight months of the order date, Beton Decken moved from manual, site‑style production to a highly automated factory with tangible results:

• Personnel effort down 30%
• Operating costs down 15%
• Production output up 20%
• Required production area reduced by 60%

Beton Decken’s plant now produces up to 18,000 m² of precast elements each week, running 22 hours a day, all fully automated, digitally managed, and even remotely controlled. With the MES system tracking every second of material use, cycle time, and quality, performance has never been more transparent or efficient.

Moving from manual processes to high performance

Before the project, production depended on manual processes and improvised workflows, which came with higher safety risks. Much of the equipment was outdated or incomplete, planning was done on the fly and digital control was non-existent. As market demand grew, this setup quickly reached its economic and organizational limits.

Despite difficult conditions, including an open hall without existing infrastructure, the company chose to rethink production from scratch. The goal was a highly automated circulation line that meets both local requirements and international efficiency standards.

Why was RIB the right choice?

Many vendors offered automation solutions, but only through closed systems that required complete machine replacement. For Beton Decken, that simply wasn’t an option.

RIB One Prefab stood out for its openness: modular software that connects to existing components, from used robots to new laser stations. RIB also brought extensive process expertise and the flexibility of both remote and on‑site technical support.

The project didn’t start with a product, it started with a shared goal. Together, Beton Decken and RIB set out to build a flexible, future-ready plant that could grow with technology, stay economically viable and raise the bar for the local construction market.

Turning a concept into a reality

In just eight months, the joint team delivered a fully digital circulation line, from planning to production start. RIB enabled what many considered unrealistic: a smooth build based on a mix of new equipment and imported used machines. The result of European-level productivity is proof of what happens when planning, software, and control all work together.

Training happened online and on-site, fine-tuning Smart Factory tools step by step to match real production. Everything from plant control to lasers, robots and quality checks, runs on one unified logic. And when the system went live, it went live as a fully operational, scalable, real-world solution, ready to perform from day one.

Tailored to the demands of the Peruvian market

In the Peruvian market, standard solutions aren’t enough. Beton Decken needs to produce slabs that are light, robust and suitable for seismic zones, with embedded conduits for power, water and gas.

RIB adapted the MES logic accordingly, with special geometries, variable openings and changing formwork plans that are modeled in the system. Flexible interfaces also made it possible to integrate used components, such as robots and circulation control.

More than just a project, a model for South America

With its new line, Beton Decken has achieved more than just efficiency gains. The plant now serves as a lighthouse project for industrial prefabrication in seismic regions, a reference model that could shape approaches across South America.

Digital control enables scaling and builds confidence among owners and investors. Further optimizations are planned, along with rollouts of similar concepts to neighboring regions and countries.

Beton Decken has laid a solid foundation: data-driven construction, efficient production and a big step forward for construction technology in South America.

Want to hear the ground-breaking story behind Beton Decken’s transformation? Tune in to RIB’s podcast Hard Hats & High Tech, where Mauricio Yui and Fernando Garbin share how they revolutionized precast construction in Peru, achieving full industrialization in just 8 months!