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Introduction to Precision Water System

Introduction to Precision Water System. Randy Willaman rwillaman@commandalkon.com (614) 799-0600 x5230. The Challenge.

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Introduction to Precision Water System

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  1. Introduction toPrecision Water System Randy Willaman rwillaman@commandalkon.com (614) 799-0600 x5230

  2. The Challenge • Production of high strength, architectural, or self consolidating concrete mixes with a sustainable approach requires precise water management in the mix to achieve performance results. Precision Water System

  3. Precision Water System A new set of tools which simplifies and automates the management of moisture compensation. Precision Water System

  4. Water Management Challenges Water added during batch Admixture materials Easy to Control (Production) Agg Moisture Slump Rack Water Water added at Job Water in the drum Difficult to Control (Transport) Precision Water System

  5. Total Moisture Compensation • PWS Software Module • PWS Moisture Interface Controller Junction Box (MIC) • Moisture Probes, up to 12 in multiples of two Precision Water System

  6. The Implementation Adding moisture measurement to an increased number of aggregates can: • Reduce slump and strength variations. • Reduce dry up loads and truck time in yard • Reduce variability at job site Precision Water System

  7. Matt Rozell, Greensburg, PA Contractor was consistently questioning the wat/cem ratio of the mix provided for the Holtwood power plant site. Problem • Installation of a four probe Precision Water System on the COMMANDbatch. Recommendation • Since PWS was installed the wat/cem ratio has been met on every batch. Production and efficiency has increased. Outcome

  8. Precision Water System Database with history of all samples Multiple bin-material-probe combinations Visual diagnostics to aid calibration Capture moisture test readings with the click of a button Simple entry of weights for calculations Precision Water System

  9. Precision Water System Calibration Graph Precision Water System

  10. Joe Shepard, Savannah, GA Waste generated from production operation due to bad concrete Problem • Installation of a two probe Precision Water System on the COMMANDbatch. Recommendation Outcome • Waste has been reduced 25%

  11. Integration • Precision Water System with COMMANDbatch • Moisture Calibration automatically changes when material is switched in a bin. • “Lock and Load” sample mode – COMMANDbatch will automatically grab probe readings for the next bake out saving time and reducing errors. Precision Water System

  12. Integration • System includes default calibrations for a range of materials, allowing immediate use of Precision Water System until bake outs and calibration occurs. • Provides long term information for QC regarding performance. • Replacement probes can be calibrated with one bake out! Precision Water System

  13. Chris Papich, CXT Concrete Buildings Struggling for 2 years with load to load spread variation on SCC. Problem • Precision Water System installed June 2011. Recommendation • Spread variation reduced from +/- 5 to +/- 1 inch.   • Bake out variation of +1% now <0.3%. Outcome

  14. The Value Proposition • With the Precision Water System, you reduce the lengthy, costly, and manual processes involved in sampling and calibrating probes. • Variations in yield and strength can be reduced. • Better consistency at the plant means less time at the plant and the job for the truck. Precision Water System

  15. Key Factors of Success • Training and Personnel • Enforcement of consistent and repeatable processes across the entire organization. • All departments must buy into the concept (Production, Technical, and Sales). • All areas of the business have to fully understand what the benefits of the system are and how to use it properly Precision Water System

  16. Delmon Readymix • After COMMANDbatch was installed with the Precision Water System the company reported a drop in the strength standard deviation from 5.5 mpa (797 psi) to 4.5 mpa (652 psi) for their mixes in the past two months. • Producing accurate slumps at the plant with +- 15mm (0.6”) achieved repeatedly, requiring less use of the slump station. The batcher no longer adds water manually to correct the slump. Jon Mottram Precision Water System

  17. Recommendation Why continue to struggle with loads that are not produced at the desired slump, increasing your costs and potentially damaging your reputation and customer satisfaction? With the Precision Water System you are on your way to more consistent loads, better yield management, lower costs, and more satisfied customers. Precision Water System

  18. Q&A “We had no confidence in our Hydronix moisture probes, I would come into work on a rainy day and have pains in my stomach. This COMMANDbatch and your web support group have made my life easy. You have taken all the guess work out of the water calculations. We are very satisfied and happy. There is no comparison to the Quadra Control and Hydronix we had before.” Wendal White, QC & Plant Manager Blakeslee Prestress Inc., Branford, CT Plant Automation: Today and Tomorrow

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