MEASUREMENT AND CONTROL UNLIKE ANYONE ELSE
A typical load of concrete from a drum has had 7 measurements taken: one for the rock, one for the sand, one for the cement powder, one for the fly-ash, one for the water, and 2 for the add-mixtures... None of these measurements is averaged or cumulative.
With Omni-Mixing Technology and our automation system we measure a load of concrete more than 200,000 times per cubic meter of concrete.
Like watching a movie in super-slow motion so you don't miss any details.
This allows us to know exactly what we are producing and be infinitely more accurate because you see exactly what is going into and can control each liter of concrete produced in a given batch.
By comparing traditional drum mixed process with our innovative technology – if we proportion the same rock in the same proportion with the same sand in the same proportion with the same cement in the same proportion with the same water in Omni-Mixing Technology™ as with a drum mixer, then test the concrete... It should be noted that every single time our concrete would break at a higher strength. We have tested and proven we are 10-25% stronger in normal distribution environments.
With respect to CSA A23.1/14, the performance criteria for any project will be:
- The project specifications for plastic concrete including: slump, air content, consistency, w/cm ratio, age of concrete, temperature, workability, place-ability, and finish-ability.
- The project specifications for hardened concrete include: compression strength/flexural strength as requested, permeability, durability (freeze-thaw, chemical attack, wear resistance) and longevity.
Each of these requirements is measurable, and a producer who has successfully manufactured a product to meet these requirements has fulfilled the requirements of CSA A23.1/14.
In a performance environment the critical aspect is the ability of the concrete to meet the project specifications. To again quote CSA A23.1:
“The advantage of the performance approach is that the contractors and materials suppliers are free to use their expertise, innovative talent, and other resources at their disposal to design and deliver the product in the most efficient and economical manner. This is consistent with the owner’s interest, which is generally to own a structure that will fulfill his or her needs at reasonable cost. In most circumstances, the owner has no vested interest in the nature of the constituent materials or the methods used, provided that the performance requirements are met.”
Mixing of Concrete
Macro-mixing is the process to ensure all the components of concrete are equally distributed through the “batch” of concrete. Macro-mixing occurs during our proportioning of concrete. For quality concrete, macro-mixing is essential to ensure every cubic foot of concrete not only contains the identical constituents, but that throughout it is ideally homogenized. Historically this is a concern with traditional mixing processes because mixing is dependent on the speed of agitation, the length of agitation and the quality of the agitation equipment. In many European countries – drum mixed concrete is being fazed out and being replaced with central mixed or dynamic mixed concrete. Our mixing method meets the criteria of wet batch plants. Mixing of concrete is critical for consistent concrete. Unlike traditional drum mixed concrete we have no risk of over mixing nor under mixing. With our dynamic mixing technology the mixing of concrete is always consistent. Because we proportion aggregates continuously, every single cubic foot of concrete is identical. Our proportioning method in essence is the macro-mixing of concrete – where accurate measures of rock, sand, cements, water, and admixtures are added simultaneously. As the components are being added the micro mixing begins.
Micro-mixing is the process whereby the cement components are combined with water and turned into a paste – that paste is then distributed to coat every single aggregate particle and the remainder of the paste is dispersed to complete the compaction. At the same time admixtures are evenly and accurately dispensed. The plasticizers come into contact with the cement particles and the dispersion (repelling) occurs. The air entrainment micro bubbles occur by friction. Our friction in our mixers is consistent, that means our air entrainment is consistent and tests have proven that our air void structure is ideal. The micro-mixing is what occurs in our mixing chambers and ensures that every single aggregate particle is coated with cement paste, admixtures including air entrainment are utilized consistently, and the final product is completely homogenous.
Historical performance is a positive indicator of future performance. Our past performance with 3rd party testing and in-house testing (1000s in total) is as follows:
2019 to date – 100%,
2018 – 100%,
2017 – 100%,
2016 – 100%,
2015 – 100%,
2014 – 100%,
2013 – 100%,
2012 – 100%,
2011 – 100%
2010 – 99% (we had one cylinder break at 29.6 MPa on a 30 MPa specification in June 2010).
Assurance of future of performance is confidence in the producer. With a positive historical track record, a very good future performance is attainable, but only if the producer is willing and endeavors to manage every aspect of the business identical to the previous years. We are willing and we will. We have proven to our current customers and will prove that not only are we a reputable and reliable producer, but we will prove that our technology is superior and our product is superior to traditional processes.
Concrete Genius’s technology provides efficiencies that the entire project can realize. We have provided acres of concrete and saved customers like you up to 27% over traditional methods. Plus, producing concrete at rates where – quoting from real customers “it would take 2 batch plants to keep up with you”. Even in close proximity to existing batch plants we have been able to produce at rates faster that 15 and 20 large drums could deliver, with just 1 mixer and 3 people.
We hope you value having a partnership with a concrete producer who is capable of producing concrete in any region, at any capacity, for any duration with unparalleled quality and consistency.