Concrete Solutions.

300 Portsmouth AvenueGreenland, NH 03840 603.431.5661 603.431.5547www.concretebiz.com

300 Portsmouth AvenueGreenland, NH 03840 603.431.5661 603.431.5547www.concretebiz.com

Con

crete Solution

s.

Concrete Problems. Concrete Solutions.

Americast Hanover Project

Americast Hanover Specs

Twin MobilMat Mo 80-Mo110-4-PCS with twin mixers feeding two separate dry cast production lines

Automatic aggregate storage bunker and batching system

4 Compartment aggregate bunker with maximum capacity approx 800 tons of aggregates. Aggregate bins are recharged directly by dump trucks

2 Cement silos, with total approx 210 tons combined storage capacity

Each mixer has a fully automatic mixer cleaning system reducing clean up time and labor

Fully automatic PCS Computer Control system for truly unattended operation

4 admixture metering control each mixer

Hydrotester aggregate bin probes automatically adjust for aggregate batch yield

Hydromat mixer probes automatically adjust batch water to maintain perfect consistent W/C ratio each batch and concrete quality

More than just a mixing and batching solution…

A leader in precast concrete storm drainage and sanitary structures, Americast, needed more than just a high capacity mixing and batching plant for greater output of concrete pipe, they needed a comprehensive productivity solution from ACT.

Project Highlights•HPGM2250Mixer#1producesa maximumdrycastconcreteoutput ofapproximately92tonsperhour

•HPGM3750Mixer#2producesa maximumwetcastconcreteoutput ofapproximately151tonsper hour

•Lowprofileaggregatebunker storagesystemhasanaggregate storagecapacityof800tons

•Twinmixerplantprovidesa maximumplantoutputcapability ofapproximately243tonsof reinforcedconcretepipeandbox culvertsperhour

Rising to the occasion, the design team at ACT started low!

The team at ACT designed a low profile aggregate bunker storage system constructed with precast box culvert segments produced by Americast. Utilizing a below grade aggregate weigh belt system, the storage solution gave Americast capacity for 800 tons, all with minimal aggregate material handling and equipment necessary. The turnkey mixing batching plant itself features twin HPGM planetary mixers working seamlessly in tandem with a Hawkeye Pipe Plus and VUP, thanks to ACT’s advanced PCS Control System. As is standard operating procedure for the solutions providers at ACT, the entire plant was delivered pre-wired and ready to go. Installation and startup were complete in a matter of weeks.

“From the design stage to startup, the process with ACT went smoothly. Two new installations since the Hanover install are benefitting from ACT’s technology.” – Don Anger, Operations Manager

Amcor Precast Foothills Specs MobilMat Mo80-4-PCS with Wiggert HPGM 2250 mixer feeding two separate production lines

Aggregate row type bins are charged by automatic aggregate material handling. The delivery truck dumps aggregate into truck dump hopper for automatic transfer into the appropriate aggregate bin. No labor or front end loader is required to charge aggregate bins

4 Compartment aggregate bins row type silo with maximum capacity 280 tons of aggregates

2 compartment split cement silos, with total approx. 100 tons storage capacity

HPGM 2250 mixer has a fully automatic mixer cleaning system reducing clean up time and labor

PCS Computer Control system fully automatic for truly unattended operation

4 admixture metering control for specialty SCC and dry cast concrete production

Hydrotester aggregate bin probes automatically adjust batch weight automatically in order to compensate for aggregate mois-ture and to maintain batch yield Hydromat mixer probes automati-cally adjust batch water to main-tain perfect consistent W/C ratio each batch and concrete quality

Amcor Precast (Oldcastle) Foothills Project

Dry cast manhole and wet cast precast solutions…

Oldcastle’s Amcor Precast Foothills required a cost-effective solution to mixing and batching that supported both dry cast manhole and wet cast production. Being able to efficiently produce SCC wet cast pipe was a critical piece of the equation.

Project Highlights•48CuYdsconventionalconcrete output/hour

•Singleplanetarymixerwithtwin dischargegatessupportstwo separateproductionlines

•UnattendedPCSControlgives plantcompleteautomation,and moreconsistentqualitycontrol

•Aggregaterowtypebin configurationallowsforautomatic aggregatematerialhandling, savingsignificantlaborandtime

Labor saving turnkey solutions from ACT were the answer…

ACT’s turnkey plant design and delivery transformed the typical months of construction and installation into a matter of weeks. ACT’s engineers also designed a comprehensive production solution that allowed for cost-effective future plant expansion as well as labor saving features that included a truck dump hopper for automatic transfer into appropriate aggregate bins, eliminating the need for labor or usual front end loaders to charge the bins.

“Our experience with ACT is always very good. During the install and setup, we never had a problem, unlike our experiences with previous vendors. I have zero complaints.”– Larry Miller, P.E.

Over half a century ago, the husband and wife team of Carl and Bertha Burkhart founded Arrow Concrete in Connecticut. Today, not only is Arrow still managed by the Burkhart clan, they’ve grown bigger than ever. And with a little help from ACT, more productive than ever, too.

Arrow Concrete Project

Better than ever.

Arrow Specs

MobilMat MO80 - MO45 - 5 - PCS

HPGM 2250 planetary mixer (for wet-cast) with 2 CuYd output

HPGM 1125 planetary mixer (for dry-cast) with microwave probe and 1 CuYd output

5-compartment, 250 ton aggregate storage bin

Hydrotester aggregate moisture probes for automatic aggregate moisture correction

HYDROMAT automatic microwave water metering

Reversible weigh belt with drive on each end, serving dry-cast and wet-cast

In-ground truck dump hopper (inside the building)

Two cement silos for cement and fly ash, with continuous level indicator cable for accurate inventory levels

Automatic mixer cleaning systems on both mixers

Radio remote call station

PCS control automation with costing and maintenance reminder & reporting

Project Highlights•TwinMixerPlantlayoutprovidesmaximumefficiencyfor wet-castanddry-castoperations

•PCScontrolrecordseachbatchproduced–criticalforDOT specifications

•Cranebucketoperatorcallsconcretebatchviaradioremote

•Temperatureprobeonmixeralertsoperatorifconcretetemp isoutofdesiredparameters,importantfordoublepouring especiallyinwinterconditions

•Consistentconcreteevenwithvaryingaggregatemoisturelevels

•Noloaderoperatorrequired(forplantsavings)

•Plantwillnotrunoutofcement,andsiloswon’tbeoverfilled unnecessarily

•Automaticmixercleaningsystemmeanslaborsavings, extendedproductionday,bettermaintainedequipment andhappieremployees

•SeconddischargedooronHPGM1125canbeusedtoaugment wet-castproductionshouldproductiondemandextraoutput

•PlantdesignedforSCCwet-castproduction

•Microwavetechnologyassuresconsistent,reliablew/cratio

Three years ago, President Kurt Burkhart, and his brother and Vice President, Ronald, decided they’d outgrown their modest facility and needed to upgrade. And with the new facility came all new equipment, too. They hired ACT to install a Wiggert MobilMat MO80 - MO45 - 5 - PCS twin mixing/batching plant. Aside from allowing stripping, set-up functions, and casting (both dry-cast and wet-cast) to take place simultaneously for production flexibility, the ACT plant also features state-of-the-art data gathering. Everything from recording the production of every batch, to self-learning “in flight” correction capabilities provide all the automation and information they need.

Upgrading two facilities.

Ultimately, the Burkharts believe the new equipment from ACT will be a huge factor in the continued growth of the family business. “It has let us increase production, cut labor, gain productivity, and increase the quality,” says Kurt, adding “and I don’t say that lightly, because our quality was very good before the new plant.”

Concrete Stone and Tile Project

Growing in an expanding market.

Concrete Stone and Tile Specs

MobilMat MO80 - 5 - PCS

COM 70–3 pigment metering system

HPGM 2250 planetary mixers with 2 CuYd output

Three mixer discharge gates

Three concrete holding hoppers with metering belts for “color mix” production

HYDROMAT microwave probe mounted in mixer floor for automatic water metering

Hydrotester moisture probes in aggregate bins

600 ton storage capacity in aggregate bins

Automatic mixer cleaning system

PCS automatic control system

Weight based AC liquid admixture scale

Traveling aggregate weigh batcher

With an expanding market and a tapped-out production facility in New Jersey, the 30 year old Concrete Stone & Tile, a manufacturer of interlocking paving stones and Versa-Lok retaining wall systems, had no choice but to expand. So operations manager Bill McGuire, a longtime veteran of the industry, knew just who to turn to for help setting up the new Montgomery, NY plant.

Project Highlights•Concretemeteringbeltsholduptothreedifferentconcrete colormixesfor“colormix”production

•PCScanbesetupwithunlimitedproductcodes,includingdifferent “colormix”sequencesforrepeatablecolormixproduction

•UnattendedPCScontrolbatchestheappropriatecolormixasthe concreteisdemandedbythepavermachine

•Batchwatercontrolledautomaticallyusingmicrowave technology–consistentw/cratioandproductcolor&texture

•Large600tonstoragecapacityallowsplanttooperatedouble shiftswithoutdeliveries-importantinwinterconditions

•Skiphoisthasanti-free-falldeviceformaximumsafety/reliability

•Consistentproductqualityduetomoisturecompensation andmicrowavewatermeteringcapabilitiesandadmixturescale

•Automaticcolormeteringsystemallowsforcustomcolorsall fromthreeprimarycolors

•Plantdesignedforeasyfutureextension

•Automaticmixercleaningsystemwithintermittent cleaningcycleallowsextendedproductionwithout cleaning&minimumcleanuptimeattheendoftheday

McGuire chose a combination of ACT systems for the new facility, including the Wiggert MobilMat MO80 - 5 - PCS with a high intensity planetary countercurrent mixer, and a fully automatic Würschum COM 70-3 pigment metering system.

ACT’s PCS Control is a system that’s second to none. In addition to batch records, it delivers reports on production, inventory, diagnostics, maintenance, and costs. And, the automatic “color mix” feature allows for a far more diverse spectrum of colors that are easily duplicated time after time. Says McGuire, “Architects and landscape architects now have a tremendous amount of versatility to color the whole project.”

One stop shopping has never been easier.

In addition to the efficiencies that ACT brings to his new plant, McGuire also likes them for their “one stop shopping” convenience. “ACT has worked very diligently to supply somebody like me with the whole enchilada,” he said. That’s why when Concrete Stone & Tile is ready to open the next plant, he knows who he’s going to call.

Rob Dalmaray, President of Dalmaray Concrete Products, set out to install a new plant in his Janesville, WI operation. Twenty years after he joined the company his father started, Rob decided it was time to make the move from truck-delivered ready-mix concrete to on-site self-compacting concrete. The challenge was to find a company that could deliver a plant to fit not only their budget, but also their dream for producing SCC within two years.

Dalmaray Project

A couple of years ago.....

Dalmaray Specs

MobilMat MO 45/2-PCS with 2 discharge gates serving 2 different bays

Automatic aggregate feeding with in-ground truck dump hopper

Capacity for 80 tons of aggregate

2 Bins

50 ton cement silo

Automatic mixer cleaning

PCS computer control system

5 Admixture controls

1 moisture probe in aggregate bin

Project Highlights•SCCProduction

•Consistentwater-to-cement ratio–QualityControl

•Quieter,cleaner,saferoperation

•Producingmoreproductsin fewerhours

•20%increaseinprofits

Rob made the decision to go with ACT. He chose them for a variety of reasons, the biggest one being that out of everyone he talked to, ACT was the only one that justgotit. Throughout the project, the only surprise has been the timeframe. Instead of Dalmaray producing SCC in two years, they were mixing it within two months.

After a year long search.....

“It’s unbelievable…once you have the right equipment, it’s amazing what you can do”, says Rob. With what many consider to be the best controlling system in the industry, ACT provides precision moisture measurement, essential to the production of SCC. And because of that precision, everything about Dalmaray’s operation is smoother (and more profitable). “It’s a much more worker-friendly environment - quieter, cleaner, and safer”, Rob reports. “And, our guys get to go home on time a lot more often, which makes them happy, while we save on overtime costs - which makes us happy, too.”

Hanson El Mirage Project

Hanson El Mirage SpecsTwin MobilMat Mo110-4-PCS with twin mixers feeding two separate dry cast production lines and an additional discharge gate for future plant expansion

4 Compartment aggregate bins row type silo with maximum capacity 530 tons of aggregates. Aggregate bins are charged directly from the truck dump hopper and the automatically material handling system

3 Cement silos, each with approx 375 tons combined storage capacity

Each mixer has a fully automatic mixer cleaning system reducing clean up time and labor

State of the art PCS Computer Control system for truly unattended operation

4 admixture metering control each mixer

Hydrotester aggregate bin probes automatically adjust for aggregate batch yield

Hydromat mixer probes automatically adjust batch water to compensate for actual aggregate moisture and to maintain perfect consistent W/C ratio each batch

Increasing output while maintaining quality standards….

ACT was brought in to Hanson Pipe & Products; El Mirage, Arizona facility to design and install a mixing batching plant that had to significantly boost production and make the most of previously installed equip-ment from another vendor.

Project Highlights

•Plantoutputwassignificantly increased

•Qualitycontrolwassignificantly improvedthroughequipment reliability,fully-automatedPCS control,andACToperatortraining

•TwinHPGM3750planetarymixers provideamaximumoutput capabilityofapproximately252 tonsofpipeandboxculvertsper hour

•Twinaggregateholdinghoppers mountedaboveeachmixerboost timecycleefficiency

ACT’s state-of-the-art technology, unparalleled service and commitment to customer success came through…

Significant expansion in capacity was the primary objective of Bryce Scofield, Project Engineer, when he turned to ACT for help. Having struggled through two previous equipment installs from two different companies, Bryce was relieved to work with a complete solution provider like ACT - who could deliver a completely automated, turnkey mixing batching plant that would work flawlessly with the previously installed components. ACT’s Twin MobilMat Mo110 quickly became the heart of the operation, giving the El Mirage plant the capability of producing roughly 252 tons of pipe and box culverts per hour.

“The install was as smooth as could be, as the plants came pre-wired with all cabling attached and in place. This saved considerable time in set up and commissioning. The ACT crew also went above and beyond in helping us modify existing equipment to work smoothly with the new ACT MobilMat plant. ACT’s PCS Control System communicates flawlessly with the outside vendor equipment, is completely intuitive to the operator, and helps us maintain quality control like never before. I’m very happy with the ACT system. It’s the third I’ve installed on the West Coast.” – Bryce Scofield, Project Engineer

The Ramsey, MN plant needed to move away from ready-mix concrete. “The costs of a ready-mix operation were just eating into our profits too much”, says plant engineer Jeff Lazar. “We really wanted to migrate to self– compacting concrete, but we knew how intricate and detailed the process was. Fortunately for us, ACT had worked with our plant in Littleton, CO for several years.”

Oldcastle MN Project

Oldcastle realized....

Oldcastle MN Specs

MobilMat MO 80/4-PCS

Capacity for 4 bins with 270 tons aggregate storage

2 moisture probes in aggregate bins

PCS Computer Control System including costing, maintenance, network to server

In-ground truck dump hopper

Automatic aggregate feeding

Double split wall cement silo — 125 tons

Automatic mixer cleaning

Ground-mounted dust collection

Project Highlights•Cutconcretecostsnearly inhalf

•Temperatureandmoisture monitoringintoughwinter months

•Inventorytracking

•Advancedsafetymonitoring

•Abilitytoshowcustomers recordsofeverybatch

Because Oldcastle’s Littleton, CO plant was so satisfied with ACT’s planetary countercurrent mixer, it was evident to everyone at Oldcastle that ACT was the way to go – with the new SCC. “The ACT plant includes temperature and moisture monitors that let us track and document everything we produce,” Lazar says. “And during the cold Minnesota winters, that’s essential. We now produce our own concrete at a cost of 40% less than what we paid for ready-mix. Not only do we save money, but we can better monitor every aspect of our production, and that really gives us peace of mind.”

...ACT was the way to go.

The Oldcastle Precast plant of Concord, NC was devastated by a fire that swept through the entire facility. But in the face of misfortune, Oldcastle decided to rebuild immediately. And they decided to take full advantage of the situation by upgrading with the best in the industry – Advanced Concrete Technologies.

Oldcastle NC Project

Back in October of 2001.....

Project Highlights•60CUTD/HourOutput

•SCCProduction

•2Min./Batch

•10Xfasterthenoldplant

•Shorterproduction day– laborsavings

Oldcastle NC Specs

MobilMat MO 80/4-PCS

Capacity for 4 bins with 270 tons aggregate storage

HYDROMAT

2 moisture probes in aggregate bins

PCS Computer Control System including costing, maintenance, network to server

In-ground truck dump hopper

Automatic aggregate feeding

Double split wall cement silo — 125 tons

Automatic mixer cleaning

Ground-mounted dust collection

The North Carolina plant was back in business – and better than ever before. “There’s no comparison between our old system and the ACT batch plant,” said Brian Rieland, Plant Manager. “It’s enabled us to run self-compacting concrete, which we could have never done in the old plant. And, our production capability has improved substantially. Where it once took 20 minutes per batch, it now takes just two minutes. And it only takes a couple of people to run the pouring process, so we save on labor, too.”

After seven months of rebuilding.....

There’s little doubt in Brian’s mind, or anyone else’s at Oldcastle, that ACT was truly the silver lining in the catastrophe they endured.

Time and money are two of the most important factors when deciding on large capital investments. And in the world of concrete production, no decisions are bigger than the ones involving your plant. Incredibly costly plants that take weeks, if not months to get up and running, have always been a concern. Until now.

SmartMix

As is the case with most businesses.....

SmartMix Specs

Available in 4 sizes (1/3 CuYd up to 1 CuYd)

Delivers consistent, highest quality in shortest time

Ideal for wide range of applications — wet-cast, dry-cast, architectural concrete, dry and wet mortar, and latest SCC concretes

Large access doors for unobstructed mixer access with special limit switches for safety

Hydraulic discharge gate for reliable operation with hand pump in case of power outage

Rugged, highly efficient drive for quiet operation

Multi-function monitoring system protects mixer against human element

Multiple water spray jets perform cleaning functions with each batch

HPGM 1125 mixer standard with torque converter for smooth start up, even under full load

Advanced Concrete Technologies announces it’s new SmartMix line of plants. SmartMix, designed by the renowned Wiggert + Company, is a versatile, compact, and economically priced batching system sure to revolutionize the industry. Says ACT President E. Max Hoene, “SmartMix plants are so easy to set up, we can get a customer up and running within three days of installation. And once they are, they’ll be doing it with incredible 80-second batch cycles for conventional concrete, producing an unheard of 45 batches per hour.”

...it’s all about profitability and productivity.

Coming in various sizes, SmartMix allows a variety of concrete production needs, including precast, dry-cast, and architectural products. Plus, they arrive on site pre-wired, pre-plumbed, and factory tested.

Simply put, SmartMix is the fastest, most efficient, and most cost effective way to produce the highest professional grade dry, and wet-cast concrete. It’s just one more way ACT works to provide the best solutions for our customers’ needs.

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Traylor Brothers Project

Furnishing a plant.

Traylor Brothers Specs

MobilMat MO80 Twin Mixer Plant

(2) HPGM 2250 planetary mixers with 2 CuYd output

(2) Skip hoists to mixer

PCS control automation

(2) Flying buckets with integral feed belts

HYDROMAT microwave probe mounted in mixer floor

Hydrotester moisture probes in aggregate bins

(3) Aggregate bins (80 tons) with reversing weigh belt

(2) Automatic mixer cleaning systems

Weight based AC liquid admixture metering scale

Two cement silos 700 BBL & 550 BBL with automatic overfill protection

Project Highlights •Customizedbatchplantmetcustomer’suniquesetof needs-feedsflyingbucketconcretedeliverysystem•2.5minutemixcycle,includingdischarge,allows highoutput•Highlysensitiveweighbeltscaleweighsaggregateand microwaveprobesautomaticallycorrectforaggregate moisture,ensuringabsoluteyieldconsistencyinquality•PCScontrolcanautomaticallydetermineactualw/cratio andaddsrequisitewater,maintainingproductionwith precisew/crationomatterwhattheaggregatedelivery orweatherconditionsare•Quick,10-minuteself-cleaningmixersallowsmixer cleaningtwicepershift–formoreproductionwithout interruptionandwithlaborsavings

•Since2002,over10,000truckloadsoftunnelsegments havebeendeliveredtovarioustunnelprojectsinthe L.A.area

*outsideoperationindesertheat

Sometimes certain projects demand the expertise of more than one company. So in February of 2001, two U.S. contractors, the Traylor Brothers and the J.F. Shea Company, partnered to build and operate a state-of-the-art tunnel segment-casting plant for a tunnel contract in Los Angeles, California.

It was decided that the most efficient way to meet the stringent requirements of the job was to set up a manufacturing facility nearby. Traylor Brothers, having successfully managed a similar on-site project before, contacted Advanced Concrete Technologies to furnish the new mixing/batching plant.

ACT came in and installed a turnkey twin Wiggert mixer plant type Mobil- Mat MO80 - 4 - PCS. In a mere 15 weeks from the time they were given notice to proceed, ACT had completed turnkey set-up of the plant…even before the contractors were ready to begin using it.

Its PCS automated control is designed to be unattended, with statistical information always stored and compiled for quality control. These and other features are the keys to always delivering precise, uniform segments, every time. Because on a project like this, there is never room for error. And that’s why ACT is always the one that can be counted on.

Ahead of schedule.

Stabil Project

Stabil, St. Petersburg SpecsMobilMat Mo80/4-PCS with one Wiggert HPGM 2250 planetary mixer fitted with two discharge gates supporting two separate crane way production halls

Aggregate row type bins are charged by front end loader

4 Compartment aggregate bins row type silo with maximum capacity 105 tons of aggregates

2 Cement silos, each with approx 150 tons storage capacity

HPGM 2250 mixer has a fully automatic mixer cleaning system reducing clean up time and labor

Fully automatic PCS Computer Control for truly unattended operation, with first in class reporting package for production, accounting, maintenance, and QC departments

4 admixture metering control each mixer for specialty SCC and Architectural concrete production

Hydrotester aggregate bin probes automatically adjust batch weight automatically in order to maintain aggregate batch yield

Hydromat mixer probes automatically adjust batch water to maintain perfect consistent W/C ratio each batch.

ACT came through for Stabil….

Increasing output and quality were the main objectives of Stabil Concrete, with their St. Petersburg architectural precast operation. A previous less than positive experience with another provider of mixing and batching plant equipment lead Stabil to contract the dedicated professionals at Advanced Concrete Technologies.

Project Highlights•48CuYdsconventionalconcrete output/hour

•Maximumplantefficiencyensured throughcompactACTskiphoist design

•Precastproductquality significantlyincreased

•Plantupandrunningquickerand tonewcapacityinshortertime

•Addedvaluearchitectural concretecapabilityisstandard withthisplant

Efficiency of plant design and installation was a winning combination….

When the ACT turnkey mixing and batching plant arrived on site, Bill Majewski of Stabil quickly realized he made the right decision. The ACT MobilMat Mo80/4-PCS would be a snap to get up and running and delivering more profitable precast concrete. Unlike with his previous experience, the ACT plant came pre-wired, almost fully pre-assembled, and ready to practically plug and play. What took months of frustration and expense to accomplish before, took a matter of weeks, thanks to the quality, ingenuity and reliability of the equipment and support from ACT.

“Our experience with ACT was as smooth as silk. Everything fit the first time, and there were enough spare parts. I would never use anyone else but ACT. They didn’t miss a trick.” – Bill Majewski, Plant Manager