Con-Fab: Transforming Prestressed Concrete Product Manufacturing
May 13, 2024
Introduction
Con-Fab, a leading manufacturer of prestressed concrete products, is at the forefront of supplying essential components for infrastructure development, such as bridge girders and parking structures. To maintain its industry leadership and commitment to quality, Con-Fab sought to overcome significant operational challenges, including prolonged demolding times, material inefficiencies, and the high costs of frequent testing, all while adhering to CalDOT’s stringent standards. This case study demonstrates how Sensytec’s sensor technology revolutionized Con-Fab’s manufacturing processes, delivering substantial efficiencies and cost savings.
Operational Challenges
Con-Fab faced several pressing issues that impacted its productivity and bottom line:
- Prolonged Demolding Times: Extended demolding times significantly limited production throughput, a critical bottleneck in operations.
- Excessive Material Use Due to Overdesign: Overdesigning products, although erring on the side of caution, led to unnecessary material usage and increased costs.
- Costly and Frequent Testing: Frequent cylinder testing to ensure quality and compliance added considerable expense and time delays to the manufacturing process.
Sensytec's Innovative Solutions
Sensytec tackled these challenges by implementing advanced sensing technology directly into Con-Fab’s production process:
- Real-Time Curing Data: Integrating sensors into the molds provided Con-Fab with real-time insights into the concrete’s curing process, enabling precise control over product quality and performance.
- Optimization of Demolding Times: Armed with accurate data, Con-Fab could safely reduce demolding times without risking product integrity, significantly enhancing production efficiency.
- Identification of Material Overdesign: Sensytec’s sensors identified opportunities to reduce material use by pinpointing areas of overdesign, allowing for the same structural integrity with less material.
Achieved Benefits
- Optimized Demolding Times: The implementation of Sensytec’s technology enabled Con-Fab to safely reduce demolding times by 11 hours, markedly increasing production throughput.
- Material Savings: By identifying overdesigned elements, Con-Fab was able to reduce material usage by up to 32%, resulting in significant cost savings without compromising the structural integrity of their products.
- Reduced Testing Requirements: Reliable, real-time performance data allowed for a 50% reduction in cylinder testing, decreasing costs and expediting the certification process.
Impact on Manufacturing Efficiency
The partnership between Sensytec and Con-Fab has set a new benchmark for efficiency and sustainability in the prestressed concrete product manufacturing industry. By leveraging Sensytec’s sensor technology, Con-Fab achieved:
- 50% Reduction in Cylinder Testing: Halving the need for cylinder testing not only cut costs but also streamlined the entire quality assurance process.
- 11-Hour Reduction in Demolding Times: This significant decrease in demolding times enabled a faster turnaround for molds, increasing the production capacity and efficiency of the operation.
Conclusion
Sensytec’s collaboration with Con-Fab illustrates the power of innovative sensor technology in enhancing manufacturing processes within the construction materials industry. Through the strategic integration of Sensytec’s solutions, Con-Fab not only overcame operational challenges but also set new standards for production efficiency, material savings, and quality control. This case study underscores the transformative potential of real-time data in achieving operational excellence and maintaining compliance with industry standards.