The REPRECT sys­tem is a paten­ted, inte­gra­ted pro­duc­tion sys­tem for the manu­fac­tu­re of straight and spi­ral pre­cast con­cre­te stairs with opti­mi­sed pro­ces­ses. It includes a new type of stair­ca­se form­work, rein­force­ment tech­no­lo­gy and rein­force­ment pro­duc­tion, pro­prie­ta­ry soft­ware for fac­to­ry plan­ning and sup­ple­men­ta­ry pro­duc­tion equip­ment.

Thanks to the cus­to­mi­sed REPRECT pro­duc­tion sys­tem, con­sis­ting of modu­lar stair­ca­se form­work sys­tems (sup­port­ed by CAD-CAM tech­no­lo­gy), spe­cial rein­force­ment tech­no­lo­gy and rein­force­ment pro­duc­tion, as well as in-house soft­ware for fac­to­ry plan­ning, cus­to­mi­sed stair­ca­ses (even for batch size 1) can be pro­du­ced quick­ly and easi­ly.

By ente­ring pre­de­fi­ned geo­me­try data, our soft­ware gene­ra­tes all the data requi­red for pro­duc­tion. This includes geo­me­try, rein­force­ment plans, form­work plans and machi­ne data.

Thanks to the quick and easy form­work con­ver­si­on, the requi­red stairs can be pro­du­ced as requi­red. This enables just-in-time pro­duc­tion.

Redu­ced steel con­sump­ti­on by up to 50% with simul­ta­neous CO₂ emis­si­on reduc­tion, mini­mi­sed mate­ri­al con­sump­ti­on, effi­ci­ent pro­duc­tion pro­ces­ses and redu­ced warehousing

For a simp­le stair­ca­se with 8 heights and a width of 1.00 m, the enti­re pro­duc­tion pro­cess, inclu­ding rein­force­ment and new form­work adjus­t­ment, can be com­ple­ted in approx. 3.5 hours.

Software-supported plan­ning and gene­ra­ti­on of pro­duc­tion data, inter­face to auto­ma­tic ben­ding machi­nes, auto­ma­tic rein­force­ment tem­p­la­te and CNC mil­ling machi­ne are used.

Yes, it is desi­gned for both straight (with and wit­hout a landing) and spi­ral stair­ca­ses.

Thanks to stan­dar­di­sed pro­ces­ses, auto­ma­ted plan­ning of plant data, high-precision pro­duc­tion tech­no­lo­gy and pre­de­fi­ned form­work and rein­force­ment ele­ments. Form­work adjus­t­ment and rein­force­ment pro­duc­tion can be car­ri­ed out wit­hout mea­su­re­ment thanks to pre­cis­e­ly spe­ci­fied steps and spe­cial pro­duc­tion tech­no­lo­gy, thus avo­i­ding errors.

Savings are achie­ved in the rein­force­ment (up to ‑50% rein­force­ment con­tent) and in the form­work set­ting (up to 70% tim­ber com­pared to con­ven­tio­nal tim­ber form­work).

The rein­force­ment tech­no­lo­gy is based on our own type sta­tics, which are based on Euro­code 2 and are appro­ved in seve­ral Euro­pean count­ries.

For straight stairs, risers with up to 21 steps, landing lengths up to max. 200 cm and sta­ir widths up to max. 205 cm (depen­ding on the form­work vari­ant) can be manu­fac­tu­red.
For spi­ral stair­ca­ses, the mini­mum side length is 98 cm and the maxi­mum side length is 520 cm. The maxi­mum width is 120 cm.
Dimen­si­ons bey­ond the sys­tem limits are also pos­si­ble for manu­al inter­ven­ti­ons.

Through ergo­no­mic hand­ling (during the requi­red acti­vi­ties, employees main­ly move direct­ly on the hall flo­or). Through auto­ma­ti­on of manu­fac­tu­ring pro­ces­ses (CNC mil­ling machi­ne) and mini­mi­sed manu­al effort, as well as spe­cial safe­ty devices.

The upright pro­duc­tion of straight stair­ca­ses crea­tes a 5‑sided clean sur­face.
The spi­ral stair­ca­ses are con­cre­ted nega­tively. The treads and risers are smooth and the under­si­de must be level­led or smoot­hed.

Our pro­duc­tion sys­tems are aimed at pre­cast con­cre­te plants world­wi­de that alre­a­dy manu­fac­tu­re stairs, want to expand their pro­duct port­fo­lio or want to estab­lish them­sel­ves on the mar­ket as a new­co­mer.

Regu­lar soft­ware updates and an easy-to-maintain form­work and rein­force­ment sys­tem redu­ce main­ten­an­ce cos­ts.

REPRECT offers a manu­al and on-site trai­ning on soft­ware, pro­duc­tion and main­ten­an­ce topics to help you get star­ted with pro­duc­tion. This enables effi­ci­ent use of the sys­tem.

Depen­ding on the initi­al situa­ti­on, mate­ri­al savings of up to 50% are pos­si­ble for steel, up to 70% for wood and up to 50% for labour cos­ts of 20%.

The cos­ts for the hard­ware (moulds, rein­force­ment machi­nes, etc.) vary depen­ding on the customer’s equip­ment requi­re­ments. The entry-level pri­ce for the TOPSTEPS sys­tem is around € 100,000.
A licence fee is char­ged for the know-how and the soft­ware. This depends on the size and pos­si­ble exclu­si­vi­ty of the licence area.

The stair­ca­se form­work, the rein­force­ment tech­no­lo­gy and the rein­force­ment pro­duc­tion are paten­ted.