- 2 days faster project completion through real-time strength data
- 30% reduction in cylinder testing reliance
- Full DOT Concrete Thermal Plan compliance maintained
- Reduced owner liability via continuous monitoring documentation
- Faster roadway reopening = less public disruption
Introduction
Webber, tasked with a critical highway construction project for the Texas Department of Transportation, faced the challenge of minimizing roadway closure times while ensuring full compliance with the DOT Concrete Thermal Plan.
Challenges
1. Efficient reopening of roadways
Reducing the time roadways were closed for repairs was the primary objective — minimizing disruption to the public and tightening project timelines.
2. DOT Concrete Thermal Plan compliance
Ensuring concrete maintained temperature thresholds per regulatory requirements was critical for structural integrity and longevity of the roadway.
3. Liability reduction
Accurately tracking concrete performance over time was essential to decrease potential future liabilities related to the project.
Sensytec’s Solution
Sensytec deployed SensyCast wireless sensors to provide continuous, real-time data on temperature, strength, and curing progress. This enabled rapid adjustments, accelerated the repair process, and ensured continuous compliance with the DOT Concrete Thermal Plan.
Key Results
Conclusion
By integrating Sensytec’s sensors, Webber exceeded project objectives — compressing the timeline, reducing testing overhead, maintaining regulatory compliance, and delivering a robust dataset that reduced owner liability.
Frequently Asked Questions
What is the Texas DOT Concrete Thermal Plan and how did Sensytec help?
TxDOT’s Concrete Thermal Plan requires concrete to maintain specific temperature thresholds during curing. Sensytec sensors continuously verified the temperature profile, ensuring full compliance and creating an auditable record.
How much faster was the Webber Texas DOT project?
Webber completed the project 2 days faster than baseline using Sensytec real-time strength data to inform reopening decisions.
Did Sensytec replace cylinder testing entirely on this project?
No. Sensytec reduced reliance on traditional cylinder testing by 30%. Sensors provide continuous data while cylinders remain for periodic verification.
How does sensor data reduce owner liability on DOT projects?
Continuous, time-stamped sensor records create a defensible quality dataset for the project, reducing liability tied to questions about concrete performance years later.