Wireless Maturity System Applications: Lowe Precast Waco, TX.
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1 Wireless Maturity System Applications: Lowe Precast Waco, TX. 1
2 Precast Concrete Plant Prior to implementing the Maturity System: Mix designs were created to drive strength in the small 4x8 test cylinders, rather than being optimized to the item being cast. Mix designs were chosen based on the speed at which the casting bed would be required again. One casting per bed per day. 700, 800, 900 and even 1000 pounds of pure portland cement was used. In addition, accelerators and retarders are routinely added. Very labor intensive operation simply to collect test samples from the sprawling plant in advance of testing. Testing is conducted at any hour of the day or night. 2
3 General Plant Layout Casting Beds A-Z Repeat Meter #1 Offices and Lab Batch Plant #1 Repeat Meter #2 Casting Beds AA-FF Approx Diameter area =Base Node =Maturity Meters The plant is approximately 0.5mi sq. With the use of repeat meters, at this time all beds are being monitored. 3
4 View of batch plant and offices from top of rock pile. Lab is ~150 from the point of photograph. One meter was deployed at this point to record ambient temperatures and act as a repeater 4
5 Wireless maturity meter with maturity sensor embedded in a test cylinder. This is how maturity curves are created. Note that the probe is in a plastic sleeve, allowing for the probe to be reused. 5
6 Employee installing repeater/ambient recorder at top of rock pile 6
7 This photo shows the batch plant in the background, with the rock pile retaining wall in the foreground. The yellow circle shows the location of the repeater unit. 7
8 The base node is connected directly to the computer where the temperature information is stored. 8
9 Wireless Maturity Meter deployed in a beam. Meter is approximately 800 feet from the base node. The laborers shown simply inserted the maturity sensor into the concrete after placement. The sensor immediately begins sending temperature data to the base node, which then is recorded in the computer located in the laboratory. The sensor is fully reusable, and the retrieval sleeve is shown in the picture below. The meters do not need to be launched or downloaded. All operations are fully automatic, with zero interaction on the part of the user. 9
10 Photo from the farthest end of the plant. Bed AA is in the foreground. The batch plant is in the far background, and is more than half a mile away. There are meters deployed all over this area. 10
11 Another deployed unit. Because this section of the plant gets early shade, both ambient and concrete temperatures are being recorded. 11
12 Unit that has been placed in a piece. The unit is oriented to point towards the base unit for maximum range. This unit was at least 2,500 feet from the base node, with other meters located in the pathway to form the mesh. 12
13 Two units deployed at the end of a long bed. A total of three units are monitoring these pieces. Continuous information is sent to the lab (in the far background beyond the building in the photo) and is evaluated by lab personnel on a routine basis. The moment the target strength in this piece has been attained, tendons are cut and the piece can be moved and the bed readied for the next pour. With the maturity system, strength and temperature information is always available instantly. These units are roughly from the lab.
14 After Implementation: Real-time test data is transmitted to the lab for instant analysis. Predictive tools allow for precise planning of stripping operations, saving labor and time. Shorter stripping and tensioning times due to higher strengths in-place. Often up to 40% reduction in curing time. Great reduction in wasted technician time collecting field samples. New information about excessive cement content, leading to dramatically lower raw materials costs. More rapid turnover in casting bed availability, possibly allowing two complete castings per day per bed. 14
15 Maturity Strength Examples The graph on the left shows the concrete temperature of a panel poured at 1:35 p.m. After 10.5 hours of cure time the panel has reached stripping strength. Below, the PSI is given based on the maturity curve that was determined in earlier tests. NOTE: The same concrete was tested by cylinders and it produced an avg. strength of 3,617 PSI in 16 hours. 15
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