Supply chain issues, inflation, and labor shortages have converged to drive the cost of construction materials up across the board. These factors are putting pressure on precast concrete producers, increasing production costs, and squeezing profit margins.
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According to the National Association of Home Builders in the U.S., materials prices increased 20.4% year over year and 33% since the start of March In addition, the World Bank predicts energy prices will rise over 50% in .
Despite the external forces driving costs higher, precast concrete producers have several opportunities to create efficiencies in their production and capitalize on new opportunities in the market for sustainable products. This article describes six ways producers can unlock more profits from their precast products:
Reducing production costs is one of the fastest ways to boost profitability. For precast concrete producers, this means reducing the use of their most expensive ingredient&#;cement. By replacing or reducing the quantity of cement required to produce quality precast concrete, producers can boost profitability significantly.
SCMs can act as a reliable replacement for cement in concrete. Studies and industry testing have proven that SCMs increase concrete&#;s strength over time to levels greater than traditional concrete mixes. The most common SCMs&#;fly ash, slag and silica fume&#;also have an added environmental benefit by sequestering post-industrial waste from coal and steel.
Recent developments, including COVID-19 disruptions, raw material shortages, and the Clean Air Act, mean SCMs may not be a long-term sustainable option. In some markets, however, SCMs are still plentiful and cheap.
Portland-limestone cement (PLC)&#;also known as Type 1L cement&#;is a blended cement with a higher limestone content. It has been widely adopted by concrete producers around the world as it works, measures, and performs the same as standard cement, but with a reduction in cement and, therefore, a lower carbon footprint.
PLC replaces up to 85% of the clinker used in regular concrete with limestone, resulting in up to 10% less CO2 emissions. It&#;s suitable for all applications, and when blended with SCMs, PLC performs similarly to regular Portland cement.
The concrete industry is facing a growing demand for sustainability. Up to 50% of commercial building developers are looking for more sustainable solutions, and suppliers across the industry are feeling the pressure to lower their carbon footprint.
This growing demand for greener building materials is partly a response to the threat of climate change as various governmental bodies and industries are working to reduce the CO2 produced in construction:
Producers that take the lead on adopting innovations to create greener precast products will be better prepared for new regulations and can position sustainability as a competitive advantage to compete for greater market share. They also have an opportunity to charge a premium for low carbon products, helping to improve profit margins.
Carbon mineralization technology, such as CarbonCure Precast, works by injecting recycled carbon dioxide into fresh concrete during mixing. The injected CO2 undergoes a chemical reaction and turns into a mineral, becoming permanently sequestered in the concrete. CO2 emissions that were once in the atmosphere are locked away permanently in the concrete.
Because it also maintains strength, carbon mineralization allows for the quantity of cement in mixes to be reduced.
This CO2 utilization in concrete is not only sustainable&#;it makes good business sense. Analysts say that CO2 mineralization has the potential to become a USD $800 billion global industry by the year as demand for greener construction materials increases.
CarbonCure is a retrofit technology that injects CO&#; into the concrete like an admixture, which is then mineralized within the concrete. The CarbonCure Precast system includes a Valve Box that connects a CO&#; storage tank to the manufacturing equipment and a Control Box that monitors the system in real-time. The easiest way to conceptualize it is to think about CO&#; as another admixture. The technology is integrated with the existing batch operation system in the same way.
CarbonCure&#;s technology has been used by a range of precast manufacturers to produce concrete products used in buildings and parking garages, and by prestressed manufacturers that have produced wall panels, decking systems and general commercial load-bearing.
Concrete made with recycled concrete aggregates is often thought to be weaker than concrete made with natural (virgin) aggregates as the recycled concrete aggregates can be less dense, have a higher water absorption and a lower crushing value than natural aggregates. It can also have a significantly increased drying shrinkage and chloride ion diffusion coefficient, creating durability concerns.
Recent tests have shown, however, that the use of recycled aggregates in concrete blocks could give a compressive strength similar to that of blocks manufactured without any recycled aggregates. Using recycled aggregates in the manufacture of concrete blocks without any natural aggregates is not economical though, since a relatively high quantity of cement is necessary to obtain the required compressive strength.
Treatment of recycled concrete aggregates with CO2 results in the mineralization of the CO2, improving the properties of the aggregates.
Precast concrete producers can boost the profitability of their businesses by adopting strategies to attract and retain talent. Some producers are noting that the adoption of innovative technology and processes is having a positive impact on hiring.
These innovations are helping to reinvigorate the way people see the construction industry as a whole and can attract younger workers to a market that&#;s facing a severe labor shortage. Further, by adopting sustainable innovations, concrete producers can attract environmentally-conscious millennial and generation Z candidates.
Contact us to discuss your requirements of post tensioning system. Our experienced sales team can help you identify the options that best suit your needs.
The concrete industry is one of the oldest industries in the world because it has consistently risen to meet new challenges head on and evolved to meet the demands of society throughout the centuries.
The challenges it faces today are no greater than any it has faced in the past, yet the innovations and technical advances in the industry are better than ever. By adopting these innovations, producers can remain profitable for generations to come.
To learn more about how you can boost your company&#;s profitability with sustainable technology, download our eBook: 3 Ways Precast Concrete Producers Can Profit From Sustainability.
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It&#;s no secret why builders use post-tensioning systems in their construction; these systems are critical to strengthening concrete used in modern large-scale building projects. The same argument applies to post-tension slabs&#;a method used when pouring the slab foundation in commercial or residential construction. This article further explores post-tension slabs and some of the advantages and challenges of their usage in construction projects.
The concrete industry started experimenting with strategies and techniques to strengthen and reinforce concrete in the s. The prestressing concept, now a standard in residential and commercial building construction, involves using a steel cable or tendon to squeeze and compress concrete before the concrete endures a structural load. As the construction industry continued refining its techniques to standardize prestressing, most builders eventually began using post-tensioning techniques for reinforced concrete slab foundations. The Federal Housing Administration officially endorsed the use of post-tensioned slabs in , and the building method is now embraced and co-opted as the preferred method for builders.
Post-tensioned slabs contain a tendon, or steel cable, that runs crisscrossed throughout the center of the slab after the concrete has already hardened. As the poured concrete dries, the post-tensioned cables stretch and tighten, which applies a significant force to the concrete slab. This technique strengthens and compresses the concrete, which helps reduce cracking and structural instability caused by unstable soil conditions in marshes, swamps, and lake areas. The process helps residential homes and commercial buildings achieve greater load-bearing strength. Post-tension slabs are more durable and stable than traditional slabs that lack the reinforcement of steel cables.
Concrete slabs have inherent structural weaknesses; they are especially susceptible to expansion and contraction due to seasonal fluctuations and changing temperatures. Anyone that has experienced winter knows that thawing temperatures usually lead to potholes, broken water mains, and cracks in the pavement. Concrete slabs are no exception. The swelling and contraction of soils based on their contact with water is another element that adversely affects the integrity of concrete slabs. Poor and unstable soils found in Southwestern states and Mexico lead to issues with soil expansion, making it difficult for builders to lay concrete slabs.
Builders depend on post-tension slabs to reduce the risks of cracking, contraction, and soil expansion and strengthen the foundation&#;s structural integrity.
Post-tension slabs are stronger than traditional concrete slabs; however, that does not necessarily mean a post-tension slab is without challenges. Read on to learn more about builders&#; challenges when using post-tensioned slabs.
Post-tensioned slabs are an excellent foundation for a new structure, but builders must plan accordingly for proper drainage. Gutters, downspouts, roof pitches, and balconies redirect rainfall. Builders need to be aware of the location of drainage as it can seep into the foundation and lead to cracks.
Laying the foundation of a post-tension slab requires professional workers, quality materials, and expert knowledge to understand the job&#;s complexity. In the building and construction industry, it&#;s essential to research the service provider and contractors you partner with before signing a contract.
Since post-tension slabs require the addition of steel tendons to strengthen and reinforce the concrete, the tendons must precisely align as shown on the blueprints. Improper tendon locations can cause uplifting, as the tendon applies more force than the weight of the concrete. As a result, the concrete might be physically lifting the slab.
Aside from producing crack-free tennis courts, smooth parking garages, and a secure foundation for someone&#;s new home, post-tension slabs offer builders an array of advantages compared to traditional concrete slabs. Here are a few of the major benefits.
Post-tensioned slabs require less concrete than traditional ones, saving builders money. Post-tensioned slabs are an investment that helps homeowners reduce the risks of concrete contraction and cracks, which inevitably costs money to repair. That&#;s why post-tensioned slabs are an initial investment worth it in the long run.
A lighter yet stronger slab of concrete allows builders to design their structure with less material and overall surface space, providing more space to build supporting pillars, walls, columns, and beams. Post-tensioned slabs are also thinner, giving builders more creative freedom when designing floors.
No matter how much planning goes into a construction project, things happen, and the idea for builders is to minimize risks. Post-tensioned slabs may help prevent cracks from forming, but concrete is not immune to the elements. The good news is that if cracks form on post-tensioned slabs, they are held together and do not spread as quickly as those on traditional foundation slabs. Therefore, post-tensioned slabs are a more durable solution.
Commercial and residential structures require rational planning and maintenance. Whether your building has a traditional concrete slab or a reinforced post-tensioned slab, building owners need to maintain the structure&#;s integrity. That&#;s why across the United States, owners and property managers rely on Valcourt as their trusted partner to protect their investments. Whether it&#;s waterproofing, restoration, or other commercial building services, Valcourt offers over 35 years of experience protecting properties from the elements. Contact Valcourt Building Services today!
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