Wind Energy Construction Concrete Provider

The Concrete Mixing Technology Designed To Build Wind Farms

Concrete Genius™ Wind Farm Concrete Provider

Concrete Genius is a technology company... not a tech company, but a company that uses technology to address industries needs.

And just over 5 years ago we were approached by two wind turbine construction contractors - who knew of our performance history, of our capabilities, and of our mobility - to see if we could address their needs.

They were frustrated by what they described as "major struggles" with supply of concrete and wanted to know if we could solve their problem of "significant project delays caused by supply quality issues."

We were confident that we had the solution for quality, but the area we had yet to overcome was the production rate. When asked where we needed to be, they said they required up to 100m3 per hour.

Those rates was unheard of at the time. But a couple days after, during a trip to Europe to investigate emerging ideas in concrete, the blueprint for our present platform was conceived.

Just two years later - after design, development, and testing - our current platform was ready for operation.


Fast forward to today, after more than 3 years of concrete production with the latest in advances and a perfect performance rating testing every aspect and providing the performance criteria's of production rate and plastic and hardened properties of the concrete... we can say, without a doubt, the Omni Mixer is ready to prove to the mass concrete industry that it will eliminate the quality and production concerns.

But there was one surprise...

We did not anticipate when we started this journey the impact this improvement in production efficiency would have on the environmental impact of the wind farm project.

Which could very well be the most important difference in some respects.

Because lets face it... if you're building a greener energy source, such as a wind farm, you should also make sure the materials used to construct it are Eco-friendly. Don't you think?

And as you can see in the following comparison chart the differences between technologies environmental impact is staggering: (*the following calculations, despite appearing to be an exaggeration, are actually true calculations based on what CSA recommends)

*To produce a 10,000m3 windmill project at 2 windmills per day (500 m3 per day).
Water used for washout
Diesel fuel used
CO2 produced during production

Batch Plant with drum/barrel delivery

*Assumed batch plant located 20-30 minutes from the project and 7m3 drums
  • Water used for washout1,0882,857 litres
  • Diesel fuel used89,339 litres
  • CO2 produced during production941 tonnes

Volumetric Mixing Technology

  • Water used for washout9,600 litres
  • Diesel fuel used8,840 litres
  • CO2 produced during production24 tonnes

As you can see: compared to drum mixed concrete from a batch plant, Omni-Mixing Technology uses only 0.2% of the water, 2.5% of the diesel fuel, and creates only 0.6% of the CO2 on a project that's main purpose is to decrease emissions and provide a greener energy source.

How is it that drastic?  Take a look at the next chart and you should start to see how the numbers are so drastically different because of the efficiency differences between the 3 technologies. Fact is, Omni-Mixing Technology is the only type of technology currently capable of providing fresh concrete on-site uninterrupted for a project of this size with only 2 mixers.

The following chart compares these same three technologies from a production standpoint for wind farm construction projects:

*To produce a 10,000m3 windmill project at 500m3 of concrete per day (2 windmills)
Measurement
Tonne movements
Required to meet production rates of 160m3 per hour
To achieve redundancy
Man hours

Batch Plant with drum/barrel delivery

*Assumed batch plant located 20-30 minutes from the project and 7m3 drums
  • MeasurementMass
  • Tonne movements48,300
  • Required to meet production rates of 160m3 per hour1 Batch Plants, 33 drum/barrel trucks
  • To achieve redundancyA 2nd Batch Plant Required
  • Man hours3,230 hours

Volumetric Mixing Technology

  • MeasurementVolume
  • Tonne movements23,000
  • Required to meet production rates of 160m3 per hour8 mixers
  • To achieve redundancyIncluded
  • Man hours935 hours

Now what about quality? (which should never be compromised, but especially on a mass pour)

With respect to CSA A23.1/14, the performance criteria for any project will be:

  1. The project specifications for plastic concrete including: slump, air content, consistency, w/cm ratio, age of concrete, temperature, workability, place-ability, and finish-ability.
  2. The project specifications for hardened concrete include: compression strength/flexural strength as requested, permeability, durability (freeze-thaw, chemical attack, wear resistance) and longevity.

Concrete Genius, using Omni-Mixing Technology, boasts an unmatched performance of 100% for 8 consecutive years success rate on all of these CSA performance tests (including air content, slump, and strength).


This same technology has been used for concrete projects building:

  • Public schools
  • Airport Runways and Deicing Pads
  • Structural and flat work for Oil Sands facilities
  • Many Department of Transportation projects
  • and many medium and large sized commercial and industrial facilities in Alberta, BC, and Alaska

...All with 100% performance


The following chart compares these same three technologies from a quality standpoint for wind farm construction projects:

*To produce 10,000m3 of concrete
Rejected loads for air, slump, or temperature
Detrimental temperature gain during production?
Air content consistency
Historical Performance: slump tests
Historical Performance: air tests
Historical Performance: compressive cylinder tests

Batch Plant with drum/barrel delivery

*Assumed batch plant located 20-30 minutes from the project and 7m3 drums
  • Rejected loads for air, slump, or temperature5-10%
  • Detrimental temperature gain during production?Yes
  • Air content consistencyHigh risk of inconsistency
  • Historical Performance: slump tests50-80%
  • Historical Performance: air tests40-70%
  • Historical Performance: compressive cylinder tests?

Volumetric Mixing Technology

  • Rejected loads for air, slump, or temperature?
  • Detrimental temperature gain during production?No risk
  • Air content consistencyMedium risk of inconsistency
  • Historical Performance: slump tests? - Entirely dependent on operator skill level
  • Historical Performance: air tests? - Entirely dependent on operator skill level
  • Historical Performance: compressive cylinder tests? - Entirely dependent on operator skill level

CSA defines a mass pour anything over 1m thick. A windmill project would be defined as a mass pour, meaning temperature is extremely important and concrete must be delivered below 20 degrees Celsius according to CSA.

At an ambient temperature of 25 degrees C, 20 degree C aggregates, 8 degree C water with a 20 minute distance from site concrete in a drum would be at 31 degrees C when it is being poured. Therefore, risk of detrimental concrete temperatures is a high risk. In those same conditions Omni-Mixing Technology would be below 20 degrees C, meeting CSA requirements.

Potential concrete problems due to high concrete temperatures include:

  • Increased water demand
  • Increased rate of slump loss
  • Increased rate of setting
  • Increased tendency for plastic-shrinkage cracking
  • Increased difficulty in controlling entrained air content
  • Decreased 28-day and later strengths
  • Increased tendency for differential thermal cracking
  • Greater variability in surface appearance
  • Increased permeability

If you can immediately remove these threats by providing fresh concrete that is accurately measured and controlled why wouldn't you?

Omni-Mixing Technology is the first platform to positively ensure W/CM ratios are in speculation. Taking thousands of precise measurement samples per cubic meter of concrete. Meaning no surprises.

And if you can use only 0.2% of the water, 2.5% of the diesel fuel, and create only 0.6% of the CO2 compared to a batch plant on a project that's main purpose is to decrease emissions and provide a greener energy source... why wouldn't you?

Contact us today at 780-284-0257 or talktous@ConcreteGenius.ca