Transforming a precast plant – Extensive modernization at Spenner Syston in Bielefeld

The Spenner Syston precast plant located in Bielefeld is currently undergoing an extensive restructuring process. As part of a multi-stage expansion plan, the plant’s entire production logistics system is being reorganized, including manufacturing equipment, material flows, and space utilization. The BFT International editorial team visited the site to get a first-hand impression of the status of the ongoing activities. The next visit is scheduled for 2026 to review progress of the first two reorganization stages.

Initial situation

Spenner GmbH & Co. KG acquired the precast plant in 2021. This strategic expansion builds upon the existing cement, lime, and ready-mixed concrete divisions of the medium-sized North Rhine-Westphalian construction materials manufacturer. As a result, Spenner Syston adds extensive, panel-type precast elements to the group’s portfolio, with the aim to merge the complete value chain under a single roof – from raw material extraction to ready-to-install components.

Strategic expansion – From raw materials to precast elements

Based in Bielefeld, Spenner Syston manufactures structural precast elements made of reinforced concrete for building construction and civil engineering projects. The company’s product portfolio includes load-bearing components such as columns, beams, floor slabs, and wall panels, but also custom elements such as stadium stands, cable ducts, and loading dock levelers. The company’s vertical integration ranges from in-house design and technical processing to on-site assembly using its own workforce. “Flat, extensive elements such as wall and sandwich panels as well as architectural concrete façades are currently in high demand,” says Managing Director Andreas Schimanski.

The plant is designed to manufacture a wide range of products, including precast elements weighing up to 90 metric tons. “We can supply structural components for the entire building shell from our own production,” says Schimanski. The company currently employs about 40 people and relies on up to 45 contract staff depending on project-specific requirements.

The Spenner Syston site’s location in the middle of a region with a large number of cement works and its link to the A2 highway make it attractive also from a logistics perspective. Its integration into the Spenner group of companies generates additional synergies in terms of business management, technology, and sales.

Reorganizing the site while production continues – A five-stage plan

The site’s structural reorganization is progressing according to a clearly structured, five-stage plan that is part of a long-term, ten-year strategy. Stages 1 and 2 are scheduled for completion by the end of 2025. Currently, the business is focusing on expanding and reorganizing central factory areas while production continues.

More specifically, plant restructuring includes the following steps until 2026:

1. Expand the storage area served by the gantry crane to increase its space by about 50%

2. Purchase two new production tables for Hall 3

- Each new table will provide a production area of 90 m² (totaling 180 m²)

- Move the large tables from Halls 2 and 1 to Hall 3

3. Move the large column form from Halls 1 and 2 to Hall 3

4. Install foundations for TT slab production[SW1]  in Hall 2

5. Move the TT slab form from Hall 1 to Hall 2

6. Set up the bending shop in Hall 1

Move the Pedax machines

Create openings to Hall 1

Purchase an electric transfer car

The scheduled activities aim to achieve more efficient material flows, shorter distances, and a clearly structured, functional layout of the production site. “Never skimp on storage space,” Schimanski stresses. “Any designated production area needs at least 1.5 times this area for storage purposes.”

The future in 2026 – Complete system rather than piecemeal approach

This transformation repositions Spenner Syston in organizational, technical, and spatial terms. In the long term, the company will operate a clearly structured plant that includes separate areas for panel-type elements, prestressed components, the bending shop, offices, and staff facilities, as well as a new carousel production line. This layout follows a flow principle that reduces material movement and paves the way to semi-automated operation.

Given the plant’s current size, this shift would allow for an annual output of 14,000 to 16,000 m³. Systematic improvement and conscious use of existing infrastructure exemplify the approach of a typical medium-sized enterprise, which is cost-conscious while also leaving room for growth. “During my career, I have already built, renovated or further developed four plants,” says Schimanski. “In my experience, our strong team here in Bielefeld is already one of the most important prerequisites for successful restructuring.”

Sustainability – Carbon emissions, CSC certification, and securing the future of the business

Sustainability is also an integral part of the company’s strategy for the plant. Spenner Syston has been certified by the Concrete Sustainability Council (CSC) and uses carbon-reduced and recycled concrete. At the same time, the company takes an even longer-term view: “At our cement plant in Erwitte, comprehensive planning is already underway for the necessary conversion of the facilities so that we can produce CO2-neutral cement in the future. This involves enormous expenditure. However, within the Spenner Group, we have the clear goal of making the entire concrete value chain climate-neutral by 2045 at the latest,” adds Schimanski.

The BFT International editorial team will continue to cover the restructuring process. The next site visit is scheduled for 2026. By then, it will be clear how far Spenner Syston has advanced in implementing its vision.