Precision Water System

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

2. Session Objective • Learn how to increase profits and consistency using the Precision Water System to measure the moisture in all of your materials. • See the process where Precision Water System captures and identifies all sources of water in the concrete. • Learn from others how Precision Water System enables trucks to be consistently loaded with concrete that is at the right slump, saving time and money with load touchup. BAT-003 Precision Water System

3. The Challenge • Production of high strength, architectural, and/or self consolidating concrete requires precise water management to achieve performance and workability results. BAT-003 Precision Water System

4. Standard Operating Procedures • Loads too wet • Perform automatic or manual dry up activity • Loads too dry • Have trucks spend extra time at slump rack or under plant • Both situations waste time and money • Trucks forced to remain in yard while mixing • Yields will be thrown off or loads rejected • Could force an extra trip • Each driver has his own interpretation of what is a 4” (100mm) slump BAT-003 Precision Water System

5. Introducing Precision Water System A COMMANDbatch module which simplifies and automates the management of moisture compensation. BAT-003 Precision Water System

6. Water Management Challenges Water added during batch Admixture materials Easy to Control (Production) Coarse Agg Moisture Fine Agg Moisture Slump Rack Water Water added at Job Water in the drum Difficult to Control (Transport) BAT-003 Precision Water System

7. Total Moisture Compensation • PWS Software Module • PWS Moisture Interface Controller Junction Box (MIC) • Up to 12 Moisture Probes BAT-003 Precision Water System

8. 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 BAT-003 Precision Water System

9. Plantsville, CT “We have recently installed Command Alkon's PWS (Precision Water System) in our plant's two sand bins. […] we have come to rely on them and have not been disappointed. [….] you need to run your own tests and input the data (Command has made this extremely quick and easy) […] We will, at some point, be adding these to our #8 and #67 (and possibly #6) bins.” See Gary's full comments on LinkedIn... Gary Radocchio BAT-003 Precision Water System

10. 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 BAT-003 Precision Water System

11. Precision Water System Calibration BAT-003 Precision Water System

12. Integration • Precision Water System for 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. BAT-003 Precision Water System

13. Integration with COMMANDbatch • 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! BAT-003 Precision Water System

14. Chris Papich Requires SCC and slump concrete out of the same plant every day. Struggling for 2 years with load to load spread variation on SCC. • Precision Water System installed June 2011. Initially had excellent results but performance had diminished. • I personally visited the site in Spring 2012. • This site provided useful information on how to better manage the Precision Water System. BAT-003 Precision Water System

15. Lessons Learned-Blended Sand While there are a lot of samples here, the range of the spread indicated that sampling results were not consistent. Much of this could have been due to bake out errors and/or different processes. Recommend that two bake outs be performed every time to reduce possibility of errors. BAT-003 Precision Water System

16. Lessons Learned – 3/8” The flatness of the response means that the probe is effectively set to one value. The question here is why was such a broad range of the “x axis” values in such a narrow band of moisture (“y-axis”)? BAT-003 Precision Water System

17. Lessons Learned - Process • Bake outs between the plant and the QC department were not consistent • Too many data points and many points were nonsensical • Reset the Precision Water System under new configuration guidelines • New samples with consistent bake out method • The mix design was corrected (!), sequences adjusted, and the batch men trained to batch the same way. BAT-003 Precision Water System

18. End Result • Spread variation reduced from +/- 5” to +/- 1”. • Bake out variation of >1% now <0.3%. BAT-003 Precision Water System

19. 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 BAT-003 Precision Water System

20. Recommendation • With the Precision Water System you are on your way to: • more consistent loads (slump within 0.5”) • better yield management • lower costs (reduction in yard of up to 5 minutes or more per truck) • more satisfied customers. BAT-003 Precision Water System

21. Q&A BAT-003 Precision Water System

22. Please Complete Your Evaluation • Be sure to circle the session you are evaluating on the back of your card • Plant Automation • BAT-003 • Precision Water System • All breakout session materials can be accessed at: www.commandalkon.com/cc2012/update/index.htm • Thank You! BAT-003 Precision Water System