From Manual Testing to Digital Control:
How One Plant Saved 500 Tons of Cement with Concremote for Precast (C4P)
A Real-Life Example of how Concremote for Precast (C4P) saves resources in Concrete production:
By switching to real-time monitoring with Concremote for Precast (C4P), a leading manufacturer saved 500 tons of cement annually by confidently optimizing mix designs and increasing the use of clinker-reduced cement – significantly reducing CO₂ emissions and boosting production efficiency.
The Challenge
Our customer faced the challenge of precisely determining the exact timing for the transfer of prestressing force and the demolding of prestressed components in order to optimize production processes and concrete mixes. Until now, this process was largely carried out using rebound testing with the Schmidt hammer.
Our Solution: Concremote for Precast (C4P)
By using Concremote for Precast (C4P), the concrete mixes used at several production sites were calibrated. Within just four weeks, the system was successfully integrated into the production process.
One of the greatest achievements was the full integration into the ERP system, allowing measurements to be generated automatically and production staff to be informed in real time about the maturity of the components.
Key Results at a Glance
- Optimization of concrete mixes and production processes based on comprehensive data analysis
- Optimization of concrete mixes by reducing the cement content (15 kg/m³) and replacing a certain amount of pure Portland cementt with a low-clinker cement, resulting in a significant CO₂ reduction.
What the Concrete Technologist & Quality Manager of this precast manufacturer says …
Thanks to direct communication with Concrefy support, we receive fast and competent assistance – whether it’s hardware-related or for calibration. The data we collect gives us valuable insights into our concrete production process and allows us to produce more sustainably and economically.
Final Takeaway
With Concremote for Precast (C4P) and the use of real-time data from the C4P Sensor in concrete production, the company not only achieved gains in efficiency but also made an active contribution to sustainability. A digital solution that makes production more efficient, cost-effective, and environmentally friendly.
