Precast concreteUpgradePublished 27 October 2026

Precast handler control upgrade in a single day

Ageing Allen Bradley controls on a rail-mounted precast handler replaced with a Mitsubishi FX5UC, a new operator HMI and Weidmüller remote IO, installed and SAT tested in one day.

Red rail-mounted precast concrete handling machine in a production shed

1 dayOn site, including installation and SAT

Off siteDeveloped and tested before the shutdown

The problem

A rail-mounted handling machine at a precast concrete plant was running on ageing Allen Bradley controls, with no operator screen to help diagnose faults. The plant needed the controls replaced without a long shutdown.

What we did

Replaced the Allen Bradley PLC with a Mitsubishi FX5UC
Added an HMI operator interface with troubleshooting screens, so operators can see what the machine is waiting for and why it has stopped
Added Weidmüller UR20 remote IO on Modbus TCP for the operator panel
Developed and tested the complete upgrade off site, before the shutdown

Handler control panel before the upgrade, with an Allen Bradley CompactLogix PLC — Before: Allen Bradley CompactLogix

The same panel after the upgrade, with a Mitsubishi FX5UC PLC — After: Mitsubishi FX5UC

One day on site

Because the software and hardware had been proven off site, the work on site was installation and testing only. The upgrade was installed and SAT tested in a single day.

Weidmüller UR20 remote IO with a Modbus TCP coupler in the operator panel — Weidmüller UR20 remote IO in the operator panel

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Project enquiry

Have a machine like this?

A few details and a photo of the panel are enough to start. You will hear back directly from an engineer.

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