By Kris Moorman
Bringing smart technology to the roadways and bridges of America takes much more than the electric-charged car zooming down the fast lane or high-tech gadgets guiding drivers. It starts, quite literally, from the ground up.
Concrete makes up about 60% of the interstate system, with more than 100,000 bridges made of this sturdy and weather-resilient material. As we look to repair outdated and deteriorating roads, bridges and highways, a growing number of contractors are looking at ways to access concrete more quickly and cost-efficiently to keep the flow of traffic moving.
Companies are enlisting the latest smart technology from the volumetric concrete industry to minimize risks while maximizing production and profitability through reduced downtime, increased efficiency, lowered materials costs, and consistent quality.
On site, on spec, and on time
A volumetric concrete mixer measures, mixes, and dispenses a precise amount of concrete from a single unit. Sand, stone, cement powder, water, and additives are each kept in its own bin to be mixed onsite and on-demand, eliminating the risks of too much or too little concrete, and hot loads (or ready-mix concrete that has begun its hydration process while still in the drum; hydration causes heat buildup in the concrete mix – thus a hot load). These are common culprits for loss of time and money.
For Ryan Lannon, superintendent with Dunnet Bay Construction based out of Glendale Heights, Illinois, finding a way to access concrete quickly and easily for the company’s heavy highway construction projects was a challenge.
“Using volumetric mixer technology, we are able to complete larger chunks on projects, such as those done for Illinois Tollway, than we would otherwise if we had to wait and get material from off-site or sub the work out to a third party,” said Lannon. “The fact that we’re able to make our mix onsite lets us control the rate of production and allows for an efficient workflow for the project.”
Most recently, Dunnet Bay Construction has been using volumetric mixers for a significant section of Chicago interstate which is used for vehicular traffic moving north and south of O’Hare International Airport. Dunnet Bay is completing a latex overlay on two bridge decks over six stages. In 2021, they completed three stages along southbound I-294, while in 2022, Dunnet Bay is completing three similar stages on northbound I-294. Each year has seen roughly 1,600 cubic yards of latex concrete being produced and placed, for a total of 3,200 cubic yards.
To repair the bridge and ensure limited gaps in access and traffic flow, Lannon and his team use a special mix design. Because volumetric technology allows jobs to be batched, measured, mixed, and poured all from one unit, sampling and testing for quality control can be done on the jobsite, and immediate adjustments made.
“The latex concrete that the volumetric mixers produce provides a very solid bonding strength to the substructure of the existing deck. It’s a cost-effective way to extend the life of a bridge and these trucks are geared up and able to produce the latex concrete in parameters set by the tollway. With these trucks, we’re able to monitor that through the process,” said Lannon.
Dunnet Bay Construction isn’t alone in its regular and growing use of volumetric mixers for roads and bridges. PRI of East Tennessee (PRI) currently has six volumetric concrete mixers in its fleet, with another two on the way. Started as an asphalt patching and concrete repair company, PRI’s project list has since grown to include Department of Transportation (DOT) paving, city and county roadway construction, commercial and industrial base paving, milling and curb and gutter and extruded curbing work, full depth trench repair and concrete/asphalt patching.
“We love the overall flexibility that the trucks offer. We get the mix designs at the touch of a button, and we’re able to pour anything from a half of a yard to eight yards at a time,” said Mike Ealey, controller at PRI.
The company recently worked on a project for the city of Gatlinburg providing shotcrete for a wet well. “With the volumetric truck, we were able to set up the truck right onsite, basically a mobile concrete mixing plant right there. We have all the materials, and we can sit there all day. We’re able to turn out hundreds of yards per day, if needed,” said Ealey.
“Full control of the project in the contractors’ hands”
As the use of volumetric mixers has expanded across the country so has the adoption of more contractors using smart technology to improve efficiency on the jobsite. Contractors are looking to technology to help them communicate and collaborate better, collect in-the-moment data to make more timely and informed decisions and ultimately manage their time, productivity, and profits.
Such smart technology allows management to connect to the office and their volumetric mixer fleet in real-time to review scheduling, completed jobs, material usage, total yards poured, customer information and any changes that might come up while the truck is in the field. Entering requested mix and quantity, directions to the jobsite, and other pertinent information allows a single operator to manage multiple jobs using the same equipment.
In addition to supporting day-to-day business operations, the tools sync data on material use, total yards poured and other historical details by job, customer and date. This information can be saved to the cloud, where management can access and review it at any time. This helps to improve budgeting and ordering while identifying cost efficiencies.
“What it comes down to is working smarter, not harder,” said Lannon. R&B
Kris Moorman is a marketing manager for Cemen Tech and has worked in construction manufacturing for over five years.
