Experiments

Friday I had the opportunity to experiment with some new admixtures in our concrete.  I always love doing this, even though I know I must drive my admix salesman nuts.  But anyway, when you experiment with new things you really get an appreciation for the equipment you have and for the advances in concrete.  As we added the new SCC admix we could actually watch the low-slump concrete turn into liquid.  We turned low slump concrete into 30” spread concrete.  If you have never seen this happen, I would encourage you to try and see this; it’s one of the neatest morphs you will ever see.  Even though we only tested 6 yards it was a lot of fun and kind of recharged the batteries.  I sat in my office that afternoon and thought to myself, “Damn, that was cool!”  I have seen concrete made over and over and over again, but when you actually create concrete it is really a good feeling.  Call me goofy, but you tweak something here, add something there, it is really cool.  It is kind of like building a house.  You have a set blue print, but sometimes you can just tweak something here or there and make what you really want to have.  I can’t wait to see the results tomorrow!

I also really take away an appreciation for our fine mixer from ACT.  When you make concrete day in and day out you don’t get a fond appreciation for how nice your equipment is until an outside set of eyes comes in and tells you this is the nicest equipment I’ve ever seen.  That’s an awesome feeling.  When someone comes in that you know has been to other plants and says you have the nicest equipment it gives you a renewal for what you have.  I know at the time when we purchased our mixer we were deciding on other mixers, but now I am glad we went with who we did because we have the best of the best.

So what I want you take away from this short blog is never stay satisfied with what you have.  You should never settle for what you were told to have.  Make your own way and keep your head looking for the better option.  And realize that things change.  Newer products are being developed everyday and you should never settle for what has been done.  Make your own way! 

The Man Next To You

Every year about this time I start to get ansy for the next construction season.  Now is about the time the phone starts ringing, bigger contracts are getting secure, and things start moving again.  The one thing I take for granted from time to time is the guys that work with me.  Everybody from the the delivery team, to the production team, to the mainenance crew they do a fantastic job and sometimes that get's overlooked.  This is not a blog to suck up to my guys.  The purpose of this blog is to direct the attention of those that work in a team environment and take for granted the man next to you.  I enjoy everyday I come into work and talk to everyone about everything.  It's nice to hear when someone has a baby on the way, or acheieved something, or even spent the weekend on the couch doing nothing.  I don't care, I enjoy hearing stories.  If you got a story I want to hear it and you know, I think more managers, bosses, owners should be that way too.  I have been on both sides of the coin and still to this day I enjoy someone asking me "hey what did you do last night" or "how was your weekend."  It really makes you feel good.  I have seen too many days where you get lost in big projects and it's like Ok get to work, work, work, work, and go home.  You get lost and derail, forget the man working next to you is are real human being and maybe he had a bad night, maybe he wants to talk, but you get lost and ignore him.  Take the time out of every day to just talk to everyone, it makes a difference.  So in all this is not a suck up, even though my guys rock ;), I just think with the upcoming construction season we can all use a lesson in being human.  Take the time to talk to the man next to you, you may learn something, but you may just make the day of the man you're talking to.  I wish you all luck this season! Stay safe, stay strong!

Good Times, Good Friends

Fresh off my recent trip to Florida for the NPCA Precast Show and fresh off my presentation on Social Media I thought I'd blog about my experience.  First thing I learned quickly...traveling with two kids under the age of 5 is a nightmare.  I don't recommend it, but hey they are just kids.  We made it down there and all throughout the trip I was able to relive my childhood by riding on roller coasters with my mother in law and watching my boys in awe as they meet and greet their favorite Disney characters.  It was very special for me.  All fun aside, the NPCA did a wonderful job this year.  You can still tell by the trade show floor that the economy is still down, but the staff did a great job making the show what it is.  One of the things I hold dear to my heart is the relationships I have formed and am still forming with the NPCA staff and other NPCA members.  At a time during the show I was invited into the "backroom" of the NPCA and I got to mix it up with some of the NPCA staff I never knew.  I had a blast with all of them and it made it me realize how lucky I am to part of such a fantastic organization.  On the plant tour I met a new precaster from Mississippi and am learning new things from him and growing a new relationship with him.  So for me the Precast Show is all about the networking.  That is why I go, that is why I am part of the NPCA.  I feel like I'm member of a big family.  A family that is not quite as special as my personal family, but they are just as giving and I hold the relationships I have just as close to my heart.  So Kirk, Claude, Roland, Bob, Ty and everyone else thank you so much for another memorable trip.   

You Learn Alot From Your Boys

One of my greatest releases from the daily grind is to sit back and watch movies with my sons Brady and Caleb.  I get excited every weekend when it’s too cold out or too rainy out because I know its movie day.  One of Brady’s favorite movies is Ratatouille, the story of a mouse who has acquired a special talent that makes him an effective chef in the kitchen just like his idol, famed chef Gusteau.  One of my favorite parts of the movie is when Remy, the mouse is talking with his father Django.  Remy and Django are arguing over life and death matters and meshing between rodent and human.  In front of a mouse trap store Django says to Remy. “Take a good long look, Remy.  This is what happens when a rat gets a little too uncomfortable around humans.  The world we live in belongs to the enemy, we must live carefully.  We look out for our own kind, Remy.  When all is said and done, we’re all we’ve got.  Remy replies, “No.” “What?” Says Django.  Remy mutters, “No. Dad I don’t believe it.  You’re telling me that the future is – can only be more of this (this being mice killed in traps)?” Django replies, “This is the way things are. You can’t change nature.”  Remy wittingly says, “Change is nature, Dad.  The part we can influence. And it starts when we decide.”  As Remy walks away Django says, “Where are you going?”  With a sparkle in his eye Remy turns and says, “With luck, forward.”  There is such a positive message in this conversation that maybe my sons don’t see, but I do and I hope they do one day.  Change is nature, but it only happens when we decide.  When we get off our asses and say I’m going to be better, I’m going to rebuild this, I’m going to write this and it’s going to be successful.  The motivation in that piece is so powerful, as buffered as it is in a Disney movie it’s still present.  I’ve been beaten down my whole life, told you can’t do that, no it will never work, you can’t do that.  You know what that does to me?  Motivates me, I love showing thet world that I don’t live to the standard, I make the standard.  That’s who I am and I hope my boys live this way too. 

            The last part of this piece where Remy says “With luck, forward” is a tremendous message for everyone.  I can’t stand being around negative backwards thinkers.  It drives me up the damn wall.  Think positive, generate ideas, and above all move forward.  The waters get murky from time to time, but if business was easy everyone would do it.  It’s hard at times, but creative thinking goes along way.  I encourage my people to bring up their thoughts; it is the only way we learn as an industry.  Owners don’t always have the best ideas.  Typically it’s the guys who do the day to day stuff every day.  Its pure ignorance of the owners to deny these people their God given right of change.  Listen, learn, and for Christ sake change.  Get out of the wheels and sprockets of history.  History is important, but it’s also a school subject.  Change isn’t.  We make change by what we do every day.  So do it and stay motivated. 

            So it’s been a blog of ranting and raving, but it’s time to change folks.  We live in a constantly changing world; let’s apply this to the way we think.  Live, learn, and listen.  Sometimes a little listening goes a long way both to the person listening and to the person speaking. 

Education is the Key!!!

This is a simple concept, yet time and time again I see this simple concept ignored and overlooked, EDUCATE.  I see this in precasters not educating customers and plumbers and pumpers not educating homeowners.  There is one thing that we do know as producers, there is a problem.  In previous blogs I have explained the nature of the Thiobicillus bacteria and how it attacks concrete.  I have also explained how precasters are helping the problem, but these are just words.  We have to be the teachers in our own mind and spread the word.  Explain to your customers that we understand we have a cancer in our industry, but we feel this cancer is curable.  It just takes time.  We need to evaluate mixes and this takes time.  The average tank failure is 7-10 years, YEARS, not hours.  If you explain to your customers that you know you have a problem, but you and your organizations are doing something to solve the problem, your customers have no reason to be upset with you.  Explain to them that mixes are being evaluated.  Tests are being done and results are coming in, but definitive answers have not been found.  The person who is in the dark and knows nothing until the problem is staring them in the eyes is the scared person.  That is the person who comes looking for answers and point fingers.  Don’t waste your time with useless guarantees and promises.  Bring the problem out to the open and don’t be afraid to admit you have a problem.  Society was built on exposing problems and fixing them.  Don’t leave your people in the dark!

Similarly, educate your homeowners.  Explain to them that there is a problem in this industry.  It is very unique and we do not have many answers yet.  Again we do not what is going on, but we need years to evaluate its effectiveness.  One of the primary questions I get asked on site in this problem, is how long will my tank last when I notice corrosion?  My answer to that is that it is very tough to estimate.  There is no definitive gauge or timeline on this problem, but the last thing you want to do is say your tank is ok don’t worry, or your tank is junk buy a new one.  A very simple answer would be it is hard to say, your tank’s structural integrity is definitely jeopardized, let’s monitor the situation and see how aggressive the attack is.  It is very easy to jot down some notes, take some pictures on what you have seen and record them for further evaluation.  On your next pumping cycle , service call, or sooner stop by.   I know we are all busy people, but monitoring and educating is the key to solving this problem.  The last thing you want to do is put your name on a guaranteed timeline.  Evaluate and Educate.  Another simple question is how did this happen?  This is usually where I put the ball in their court.  Ask them simple questions, what kind of cleaners do you use? Have you been taking prescription medications?  How many people are living in the home? Do you have any information regarding the groundwater and surrounding ground conditions? Any relevant information?  People tend to feel better if they are part of the solution and you would be surprised how many answers you can get from homeowners.  Again don’t ignore this problem.  It will not go away.  Instead bring it out in the open and EDUCATE!

MIC part 2: Quality Concrete

Continuing on with discussion of MIC in septic tanks we have first identified what the problem is, now it is time to talk about solutions.  Although many additive solutions are present at this time, none have been properly tested in these situations as this is a time dependant problem.  Therefore, only time will tell if newer additives in concrete will help aid the concrete's resistance to corrosion.  The one definitive we have as precasters, is the ability to produce a quality product for your customers.  Above all others, producing quality concrete is a good starting place for fighting MIC.  With an inadequate mix, the Thiobacillus bacteria essentially has less work to do to destroy your customer's septic tank. 

Now what is meant by an inadequate mix?  Inadequate mixes are those that have reduced strength and improper water to cementitious ratios.  Right now, most codes specify either a 4000 or 5000 psi concrete compressive strength and a water to cementitious ratio no greater than 0.45.  That being said, why are we still finding concrete with water to cementitious ratios in the 0.50's and strengths less than 4000 psi?  It is my opinion that this is largely due to inadequate eduction, lack of care in what we produce, and given the times a reduction in product costs to keep prices down.  I will say, though, that now is not the time to save pennies by making less quality products.  Now is the time to get educated and make the best possible product for customers!!! 

Cement requires very little water to become hydrated enough to start the process of forming paste.  The rest of the water goes toward aiding in workabilty and making the concrete easy to form.  However most precasters should have access to admixtures that can aid in workability without the addition of adding water.  Using modern superplastizers there is no reason why a precaster cannot get his/her water to cementitious ratio down around the .40 region or lower.  And the lower the water to cementitious ratio, the lower the amount of pores in concrete, thus making a very durable product.  Modern self compacting concrete admixtures can make concrete almost like water while still maintaining high strength and low porosity.

In addition strength is something we have great control over.  Cement is typically the number cost in a concrete mix design.  The more cement the greater the cost in your mix.  However, the more cement the higher the strength.  Given the recent economic scale, it is easy to try and cut cost by making a less cement rich mix.  This, however, is not the right move!!  I would be the first to caution, cutting cost by making a more inferior product is not good practice.  Most codes specify a 4000 psi concrete for tanks.  Recent studies have found that concrete around 5000 psi or higher will stand up to more adverse conditions than a 4000 psi mix.  Some municipalities even spec a 6000-7000 psi mix for wastewater applications. Again, given the advances in concrete admixtures a 5000 psi batch is not hard to attain by today's standards.  Setting the bar at a 5000 psi minimum is a great starting point. 

In addition to mixing adequate concrete, checking and testing is also just as important.  One should keep constant monitor on what is coming out of the mixer.  Check your air, check your strengths, check your yields.  Keep tabs on everything.  That is the only way to learn!  The days of mixing on the fly are over.  Engineers and GC's are demanding more and more of us everyday, keep yourself in check.  Also, use your resources.  Talk with your cement salesman, talk with your admix salesman find out what is going on in the industry.  Put them to the test, tell them what you want out of your concrete.  Keep yourself educated!!!

To summarize this I'm going keep this short and sweet.....THERE IS NO SUBSTITUTE FOR GOOD QUALITY CONCRETE...Learn it, live it!

Microbially Induced Corrosion in Septic Tanks pt 1

Microbially Induced Corrosion or MIC has been a problem with the concrete industry for years; however, it's impact on the precast industry has really been brought to the forefront recently with the discovery of rapid corrosion in septic tanks.  Septic tanks that normally have a service life 30-50 years are failing in a matter of years.  There are many aspects of this problem from how does the MIC happen to quality of concrete to actual relevance in an already struggling infrastructure.  Although it is my intent to cover most of these issues in most parts I would first like to start with an introduction.
MIC is a form of corrosion that is very dependant on bacteria.  Naturally occuring bacteria in septic tanks exrete hydrogen sulfide gas (rotten egg smell in sewerage).  Now this gas naturally stays dormant in septic tanks, until a form of turbulence is introduced.  When the turbulence is introduced the gas is released and floats in the air space of the tank.  Another occuring bacteria the thiobacillus bacteria converts the hyrogen sulfide gas into hydrosulfuric acid which eats concrete.  So looking at this from the outside you say ok eliminate the sulfur production or the thiobacillus bacteria and everything should be ok.  However it is those two aspects that make this problem one of the hardest to figure out.  Where does all the extra sulfur come from? Medications? Foods? Cleaners? Fertilizers?  How do we kill the thiobacillus bacteria?  There are modern additives that can be put in concrete to kill the bacteria, however I have not had the chance or heard from a first person perspective how effective the additive is.  Another approach is to realize that the thiobacillus bacteria cannot strive on surfaces with pH's greater than 9.  Fortunately or unfortunately, concrete is very basic pH 12-14.  It is the progression of the wastwater becoming more and more acidic that allows the thiobacillus to grow more prevalent on the concrete surface.  So as you can see, this problem just from the beginning is really complex.  In future blogs I plan on touching on topics such as quality concrete, coatings, additives in concrete, impact on infrastructure, the future of MIC, and other topics so stay tuned.   I leave you with a few pics to see how bad this problem is.  Thanks...Aaron