Production of stairs in The United Kingdom
Flexcaster
Fully Adjustable Stair Mould for Precast Stairs with Landings
The Flexcaster by Construx-Weckenmann is an intelligent, motorized stair mould developed for the production of precast concrete staircases with top and bottom landings. Built for maximum flexibility, it allows for fully adjustable goings and risers, quick setup, and seamless production of straight stair flights with steps cast upside down (treads facing downward). It is the perfect solution for complex stair designs and modular production environments.
Advanced Motorized Adjustment System
The Flexcaster uses two electric linear actuators, controlled via:
- Touchscreen-operated PLC (Programmable Logic Controller)
- Remote control panel
This setup allows:
- Simultaneous adjustment of tread depths (goings)
- Uniform adjustment of riser heights
Adjustment Ranges:
- Goings: 200 mm to 320 mm
- Risers: 150 mm to 200 mm
This dual adjustment system provides fast and repeatable configuration of stair geometries in less than 3 minutes.
Customizable Stair Mould Design
- Standard mould width: 1.5 m
- Optional width: up to 4 m (enables casting of 2 staircases side by side)
- Adjustable number of steps: typically 10 to 26
- Longer moulds (20+ steps) can cast 2 short stair flights simultaneously
Tilting Function & Side Panel Adjustability
- Optional electric tilting device for:
- Easier rebar installation
- Faster stair removal
- Improved mould cleaning
- One side of the mould features a height-adjustable panel, allowing the stair thickness to vary from 120 mm to 300 mm.
- Wider, non-tilting versions can be equipped with a second adjustable panel for balance.
Integrated Landings – Top & Bottom
Includes two sets of landing formwork:
- Bottom landing:
- Constructed as an extended first step
- Angle adjusted manually via 2 synchronized spindles
- Top landing:
- Mounted on a movable carriage
- Can be positioned flexibly along the mould length
- When fixed at the rear, it synchronizes with step adjustments
- Angle also manually adjusted via 2 spindles (or optionally motorized)
Articulating Step Fronts & Finishing Options
- Most common step design features an articulating front plate with a recessed support face (18 mm)
- Compatible with:
- 18 mm plywood inserts
- 3 mm metal plates with 15 mm screwed-on plywood
- Cut-back and nosed steps: formed using triangular magnetic chamfers, allowing for up to 40 mm overlap
PLC Automation & Digital Control
- Operator inputs riser height and tread depth via touchscreen
- System checks all safety sensors and automatically adjusts all steps and landings
- Cycle time for a complete setup: approx. 3 minutes
- Visual feedback shows:
- Exact landing angles
- Pressure beam and side-form positions
- “Cleaning mode” moves the mould to its open position for easy access
Optional PLC Upgrade:
- Electric actuators for top and bottom landing angle and position control
- Enhanced safety, process accuracy, and lower maintenance effort
Key Benefits
- Fully adjustable risers and goings via 2 motorized systems
- Supports upside-down stair casting with landings
- Fast configuration: set up new stair geometries in minutes
- High flexibility for step types, landings, and widths
- Compatible with automation, PLC, and digital diagnostics
- Reduced setup, demoulding, and cleaning times
