A Monolithic Ready-Mix Race Against Time
In an effort to streamline this race against time logistical nightmare, Silvi leveraged their association with GivenHansco of Columbus, Ohio, a leading developer of producer-driven software for the ready-mix construction industry, and their integrated Keystone suite of advanced accounting, batch control, dispatch, and GPS vehicle software solutions. The goal was to deliver 600 yards of ready-mix concrete per hour over a 12-hour periodâˆ’continuously implementing 106 trucks from three central ready-mix concrete plants to the foundation site.
The BAPS project represented the largest continuous concrete pour in Silvi's history, requiring a perfectly executed timetable and plan of attackâˆ’where the slightest error in judgement and planning could represent the potential for catastrophic failure. Countless hours of advanced meetings were required to discuss the possible problems that might occur and to formulate solutions to those challenges. Silvi also assigned 20 additional employees on site to assist in quality control, traffic management, and truck placement.
According to Jeff Davis, Silvi's Director of Dispatch, "Given the short time-frame, staging the traffic patterns for the trucks was a must and the ticketing of 700 truckloads of material was key for success." Davis also emphasized that pushing the 106 trucks through faster was critical, as the drivers were only allowed to work 12 hours per day legallyâˆ’ effectively calling "time" and losing the trucks after 12 hours.
At 5:45 a.m. on the day of the placement, 40 trucks started rolling on to the site. Upon arrival, after a Hindu priest's ceremonial blessing at the project's start, they began feeding five pump trucks strategically staged around the foundation. Special care to accommodate rotated timing to slot spaces for all the trucks was also of considerable concern.
Efficiency of the material supply chain is critical to batch concrete with on-time deliveries to the plant, while moving a lot of material in a short amount of timeâˆ’as was the case with the BAPS project. Silvi's automated, high-capacity modern plants, trucks, and experienced personnel were able to manage and facilitate emptying a full truck of concrete every 60 seconds within the project's 12-hour time limitâˆ’with an assist from GivenHansco's Keystone products working seamlessly in the background. (See sidebar)
Beginning at 5:45 a.m. and finishing a little after 5:30 p.m., Silvi's last truck discharged into the formsâˆ’ culminating in a 7,029-yard BAPS pour without any interruption. It was the largest single pour in Silvi's history and one of their biggest accomplishmentsâˆ’likewise for the Keystone software suite.
Silvi's Davis emphasized that preparation, planning, and ingenuity across all parties and platforms were key to overcoming the BAPS's pour challenges and ultimate success. In respect to GivenHansco's integrated Keystone software products Davis noted, "It allowed us to maximize every last drop of efficiency out of whatever resources we had in action on the project. There were no lags in tickets, no waits from plants, as well as approved mixes, immediate driver tracking, centralized reporting, and cost control analysis. Most importantly, GivenHansco's customer service was impeccableâˆ’if there was any problem they were right there at the make of a call."
Currently, Silvi is using GivenHansco's Keystone products for all nine of their operating plants; including three new ones, which were integrated easily into their system. Notably, they are the preferred customer for field testing of GivenHansco's new Keystone On-Demand Mobile Appâˆ’an extension of its advanced Keystone Dispatch, Truck Tracking, and Financials suite. On-Demand is an innovative mobile app providing live business intelligence to ready-mix sales personnel, plant managers and owners in the field.