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Gypsum Solutions

Selecting a Pump to Maximize Productivity and Profitability in Gypsum Applications

By Tripp Farrell, President, Blastcrete Equipment, LLC

New construction is on the rise across the country – especially for multi-family residential units, where completions are at record numbers and show little evidence of slowing down into 2020. These projects create an ideal environment for contractors looking to break into or grow their business in high-flow material markets with gypsum floor underlayment, grouting, cellular concrete, plaster and stucco applications. 

Recent advancements in rotor-stator technology led to the introduction of an adjustable rotor-stator pump with inline pressure gauge to the gypsum mixer/pump market. This innovation allows contractors to adjust flow to meet a project’s unique requirements, resulting in less wear and tear on pump components

However, success in this field requires an investment in specialized equipment – a limiting factor for many bottom-line-conscious contractors. While there is no way to offset equipment costs altogether, recent innovations in gypsum mixer/pumps have made these units more affordable, user-friendly and versatile than previous options. With the right equipment, contractors can see quick ROI and increased efficiency.

Here are several key factors to consider when selecting a gypsum mixer/pump to maximize productivity and profitability.

Pump Type

The type of pump is perhaps the most important feature to consider when investing in a gypsum mixer/pump. For contractors considering lower output gypsum applications such as radiant heat, smaller and more economical peristaltic/squeeze pumps can be used successfully. However, squeeze pumps will surge, which results in a light interruption in material flow. Minimal surging can lead to splatter on drywall, resulting in unnecessary cleanup. The squeeze pump has a maximum 450 psi line pressure which limits pumping distance to around 300 feet.  

Rotor-stator pumps, on the other hand, provide continuous flow, eliminating surges and increasing productivity. These pumps can generate up to 600 psi of pumping pressure – about 30 percent more than squeeze pumps – for pumping distances in excess of 150 feet vertically and 500 feet horizontally. 

Gypsum mixer/pumps that can be charged directly with a specially designed skid steer bucket not only saves time and energy; they allow contractors to set up sand and gypsum stockpiles in a separate location when space is at a premium. 
 

Recent advancements in rotor-stator technology led to the introduction of an adjustable rotor-stator pump with inline pressure gauge to the gypsum mixer/pump market. This innovation allows contractors to adjust flow to meet a project’s unique requirements. Tightening the rotor-stator results in maximum pumping distances, which is ideal for high-rise and long-distance jobs. When the job requires shorter pumping distances – between 200 and 300 feet – contractors simply loosen Gypsum mixer/pumps that can be charged directly with a specially designed skid steer bucket not only saves time and energy; they allow contractors to set up sand and gypsum stockpiles in a separate location when space is at a premium.  rotor-stator. This flexibility results in optimum pumping pressure for the application. 

Adjusting the pump to fit the application specifications results in less wear and tear on the rotor-stator since these are the primary wear parts on this style of pump. Monitoring and adjusting the line pressure helps contractor double or even triple the life of these components. To further minimize lifetime maintenance costs and unnecessary downtime, some OEMs design their adjustable rotor-stator pumps with easy access to mechanical seals. This user-friendly design allows operators to perform mechanical seal maintenance without dismantling the rotor and stator, drastically reducing labor expenses and saving hours of unnecessary downtime. 

Price Point

No product selection discussion would be complete without touching on price. Cost is an important factor in determining the value a piece of equipment brings to a business and whether it’s worth pursuing. In the past, a limited selection of gypsum mixer/pump models meant contractors looking to invest in gypsum equipment might be stuck with a higher price tag and unnecessary features for their operation. 

The type of pump is perhaps the most important feature to consider when investing in a gypsum mixer/pump. Rotor-stator pumps provide continuous flow, eliminating surges and increasing productivity.
 

A lack of specialized gypsum equipment options also led some contractors to purchase units designed for more general cementitious applications – a situation that came with its own host of problems. However, as the gypsum industry continues to develop, more economical mixer/pump options with simpler and more user-friendly designs are filling the gap, offering contractors the ability to select equipment based on their needs without overinvesting.

Prices for a new gypsum mixer/pump can range from $45,000 to well over $125,000. Comparing apples to apples in terms of capacity and output, contractors will find minimal difference between most gypsum machines. The industry average is 12-cubic-foot mixers and pumping speeds well over 100 bags of gypsum per hour. 

Differences arise with a closer inspection of the spec sheets. Contractors looking to not pay for more than they need should contact manufacturers to walk through what features are necessary for their specific operation. For example, engine size can play a huge part in price differentiation. Gypsum mixer/pumps range in size from 3,350 pounds with a 32-horsepower engine to nearly 10,000 pounds with a 100-horsepower engine. 

Exactly how much horsepower is necessary will depend on the target applications, so discussing options with OEM experts is important for making the most practical and economical decision. While gypsum mixer/pumps are not totally customizable, partnering with certain OEMs allows for a more personalized result, often with a significant cost savings over standard models. 

Simplified Design

The saying “less is more” often applies to gypsum mixer/pumps. In addition to reducing the initial cost, selecting a reliable gypsum mixer/pump that does the basics and does them well often results in a user-friendly unit that’s easy to operate, maintain, and keep clean.

Hydraulic spiral mixers offer a benefit over paddle mixers since they can operate at higher speeds without splashing or throwing material out of the mixer. This mixer also limits possible maintenance issues and unnecessary downtime by minimizing moving parts.

To make the most of an equipment investment, the machine needs to have high utilization. For contractors looking to operate at multiple jobsites with multiple crews, selecting a gypsum mixer/pump with the essential components and no frills equates to less training, less downtime and less stress. Machines with a simple, intuitive design are easy to operate with minimal training. This opens up the door for maximum productivity since contractors can train several crew members and still deliver quality results.

Fewer moving parts also means less mess and less maintenance. A unit’s mixer is a good example of this. Most units feature either a paddle type mixer or a hydraulic spiral mixer. Both work quickly, mixing a full load in about two minutes. However, hydraulic spiral mixers offer a benefit over paddle mixers since they can operate at higher speeds without splashing or throwing material out of the mixer. This leads to increased productivity since crews are not spending unnecessary time cleaning. 

Additionally, the paddle style mixers used in gypsum equipment usually have two mixer shafts, which doubles the moving parts. Compare this to a single planetary gearbox driving the spiral mixer. With features like spiral mixers, new gypsum mixer/pumps limit possible maintenance issues and unnecessary downtime by minimizing moving parts.

These time-savings aren’t limited to major maintenance. Proper cleaning is vital for any concrete pump, including gypsum equipment. The less there is to clean, the faster this process will be. Look for a model with easily accessible wear parts to make daily cleaning as efficient as possible. Some manufactures have gone a step further to simplify maintenance by engineering a removable mixer and pump kit that simply detaches from the machine for the ease of cleaning and scheduled maintenance.

Maneuverability

Transportability is another key consideration when selecting the right mixer/pump combination. The larger and more remote the contractor’s service area, the more vital this becomes. Units featuring robust trailers for long-distance travel and a lighter footprint provide a more practical solution for extended service areas. For maximum maneuverability, look for a unit with a dual axle high-speed towing trailer and tubular steel frame to enable safe travel on highways. 

Onsite maneuverability is another area to keep in mind. Once the equipment has arrived, its placement and use can be quite the logistical challenge – especially on crowded jobsites. A gypsum pump with a smaller footprint can increase overall productivity. The charging process for different machines is a good example of this. Some models include a skip hoist to charge the mixer. The hoist is filled with sand and gypsum either by hand or with a skid steer bucket. When full, it rises and dumps into the mixer. 

This system requires sand and gypsum material to be stored near the pump and ample space for the hoist to maneuver, limiting where contractors can set it up. Gypsum pumps without the skip hoist eliminate the additional step and can be charged directly with a specially designed skid steer bucket. This not only saves time and energy; it allows contractors to set up sand and gypsum stockpiles in a separate location when space is at a premium. 

Customer Service

As with many equipment decisions, brand is an important factor to consider when selecting a gypsum mixer/pump. The right machine will ultimately be the one with the ideal combination of features and price, but the service and support behind that unit can’t be discounted. Partnering with a manufacturer that has a reputation for robust, high quality machines means operators can expect fewer breakdowns over its lifetime. Plus, when parts and service are required, knowing the team behind the brand is available 24/7 can be a huge relief. From fast delivery of parts to expert troubleshooting, dedicated OEMs help their customers increase efficiency.    

Making the Right Selection

The surest route to success in any business starts with investing in the best equipment to get the job done quickly and efficiently. Recent advances are making it easier and more economical for first-time and veteran gypsum contractors to take this step, but there are still many factors to consider. From design to durability, selecting a gypsum mixer/pump for maximum productivity and profitability must begin with the contractor’s unique needs. 

This feature appeared in the December 2019 issues of the ACP Magazines:

California Builder & Engineer, Construction, Construction Digest, Construction News, Constructioneer, Dixie Contractor, Michigan Contractor & Builder, Midwest Contractor, New England Construction, Pacific Builder & Engineer, Rocky Mountain Construction, Texas Contractor,
Western Builder

Workflow Verification Technology

By Jeff Winke

 A Scanning Robotic Total Station Combines Two Functions for Increased Productivity

In the 1950s, Ace Books began publishing Ace Doubles, which were two separate novels combined in a single volume. For example, a reader could read “Secret Agent of Terra” which ends at about the middle of the book. The reader could then close the book; do a head-to-toe flip of the volume; and there would be the cover of the second book, “The Rim of Space.” The reader is happy because they get twice the value– two separate novels for the price of one. The two-novels-in-one book concept clearly provided great value to the avid reader.

That same kind of value proposition can also be seen in a new product for construction workflow verification. Available from Topcon Positioning Systems, Livermore, California, the GTL-1000 is a compact scanner integrated with a fully-featured robotic total station, offering a site manager a dual-function instrument designed to complete a layout and scan on a single set-up. The data can be processed, mapped, and provide construction verification.

“The key benefit that got me most excited by combining layout and laser scanning into one device is placing that device in the right person’s hands,” stated Taylor Cupp, Technologist with M. A. Mortenson Company in Minneapolis, Minnesota. “On our projects, that is the layout professional – now we can empower them to not only do layout, but also capture what is built for quality control. It’s very beneficial because the person that knows how they’ve set up the job in terms of control points and those kinds of things can be the one to do that capture and get it as accurate as possible with one device.”

Topcon describes it as a first in the industry that all workflow components are integrated and provides users with a live, “as built” model of projects, allowing the contractor to identify and rectify any discrepancies. 

“Our field engineering team has expressed interest in a product like the GTL-1000 for many years – a product that allows them to survey and scan within the same workflow and not have to spend time in the office registering scan data,” stated Paulina Acosta, Senior Applied Technology Specialist with Rogers-O’Brien Construction in Dallas, Texas. “Each point cloud is geo-located before you leave the field. This makes them feel confident that the point clouds will be correctly positioned to our 3-D models, without the need for visual alignment or the need to return to the field to acquire more data in order to make the registration work.”

Nick Salmons, Principal Laser Scanning Surveyor at Balfour Beatty Construction in London, United Kingdom, said, “The new Topcon robotic scanning solution will increase productivity on site by accelerating the construction process and identifying design challenges more efficiently than traditional methods.” 

Salmons also said it will benefit the industry as a whole by “reducing cost and program duration, for both clients and contractors alike.”

Ease of Use

The system is designed so the user can initiate a scan with the press of a single button. A full-dome 360-degree scan can be created in a few minutes, according to Ray Kerwin, Topcon Director of Global Product Planning. “More traditional systems and methods take considerably longer,” Kerwin said. “So, depending on the job site conditions, a contractor can get in and out quicker and thus minimizes safety concerns.” 

A benefit Acosta likes: “We liked the ability to take individual as-built points with the GTL-1000 after it completes a full scan. This is helpful when you are trying to ensure that you captured the center point of a sleeve or a structural connection. These points appear in the point cloud after they are processed and eliminate the time spent by our 3-D modelers trying to determine the positioning of specific items in a point cloud.”

The scanner is used in combination with ClearEdge3D Verity, a software tool designed to automate construction verification.

“The seamless integration of the unit and Verity creates a complete package that is perfect for construction verification using 3-D modelling techniques,” Kerwin stated. “The result is a system that offers full-dome scanning which can quickly capture duct work, columns, beams, girders, flaps, penetrations, and structural steel. It helps to improve quality assurance, providing clear visual indication of construction-quality heat maps to minimize the effects of mistakes before they become expensive problems.”

The system is designed to build upon proven prism tracking and accuracy that allows operators to establish points in most construction environments. The product includes on-board MAGNET Collage field software designed to process the data and offer real-time field-to-office connectivity. 

Increased Efficiency

A key productivity benefit of the scanning robotic total station is that the site engineer requires no additional training and does not need to rely on outside scanning services. The new system is designed to take what was previously a rather lengthy, specialty process and compresses all the steps, reducing the overall verification time. The infrastructure group Balfour Beatty originally tested the GTL-1000 in the field. 

“In our use and testing, we have found that the new robotic scanning solution will increase productivity on site by accelerating the construction process and identifying design challenges more efficiently than traditional methods,” Salmons said. “We are delighted to have collaborated with Topcon over the last 12 months to trial this new tool, which will significantly benefit the industry as a whole; reducing cost and program duration, for both clients and contractors alike.”

The benefits of the combined scanning robotic total station are also said to extend to subcontractors, who can share the verification data, meaning all parties are working from the same construction-quality heat maps. For example, the first electrical ducts and conduits can often cause problems, as alterations can often occur that go unnoticed. With Topcon’s new system, the speed at which everybody working on the job can understand mistakes means the effects can hopefully be minimized before they become expensive problems.As efficiency becomes increasingly important in the market, time cannot be wasted and mistakes cannot be tolerated. Clearly, the demand for quick construction verification is on the rise, which supports the need for new technologies that can 

This feature appeared in the December 2019 issues of the ACP Magazines:

California Builder & Engineer, Construction, Construction Digest, Construction News, Constructioneer, Dixie Contractor, Michigan Contractor & Builder, Midwest Contractor, New England Construction, Pacific Builder & Engineer, Rocky Mountain Construction, Texas Contractor,
Western Builder

Be OSHA Ready

Knowing Your Rights Will Help Protect Your Organization if OSHA Comes Knocking

By Samantha Monsees

Fisher Phillips

Picture this. You’re in the middle of a large project and OSHA shows up at your worksite. Standing before you is a government agent whose sole purpose is to identify and cite safety hazards at your worksite. A knock from OSHA (or any government enforcement agent) is disruptive, stressful and intimidating. But don’t panic. You have far more rights than you realize, and when OSHA knocks, you can (and should) assert those rights to protect your organization. 

Reasonable Time, Reasonable Manner

Unless you are in the unfortunate position of having just reported a serious injury to OSHA, you will not know when OSHA is coming. In most situations, it’s illegal for OSHA to give you advance notice. As Murphy’s Law dictates, OSHA will show up demanding an inspection during your busiest time of day, or when your project manager is out sick or you’re shorthanded. Section 8(a) of the OSHA Act authorizes OSHA to inspect your worksite, but the good news is this same provision requires that the manner, timing and scope of the inspection be reasonable. 

Opening Conference

Keeping this reasonableness requirement in mind, the opening conference is your opportunity to determine why OSHA is there and to negotiate a reasonable scope before the inspection begins. It is a best practice to designate a conference room or other office to conduct the opening conference, which is away from and out of view of your construction site.

Similar to your right to demand a warrant from a police officer who shows up at your house, you have a Fourth Amendment right to demand a warrant from OSHA before letting a Compliance Safety and Health Officer (CSHO) inspect your worksite (unless there is the presence of an imminent hazard). Once OSHA returns with a warrant, they will most certainly scrutinize your worksite more harshly than if you had cooperated initially. On the other hand, if you are unable to reach an agreement with the CSHO on the scope of the inspection or you need additional time to allow the proper representatives to arrive to your worksite, a warrant may be appropriate. This is determined on a case-by-case basis, and you should consult counsel before demanding a warrant. 

Walk-Around

After you agree to the proper scope of the inspection, you (and your counsel) have the right to accompany the CSHO throughout the inspection. If there are other employers (such as subcontractors) on your worksite, it is a best practice to have a procedure in place for notifying the proper representatives of the other employers that OSHA is on site.

Take detailed notes of what the CSHO is doing during the walk-around, which employees are being observed and anything that is said by management or OSHA. The CSHO will want to take pictures and videos during the walk-around inspection. You have a right to – and should – take the same pictures and videos as the CSHO. If the CSHO wants to take samples or perform testing, you have the right to advise OSHA you do not consent to testing unless and until you are able to perform a side-by-side test conducted by an independent industrial hygienist or other specialist. Down the road, it will be difficult to challenge the results of OSHA’s testing without having your own test to compare.

Because the CSHO is using the inspection to collect evidence to support citations, managers should not volunteer additional information that is not requested and certainly should not admit that he or she is aware of a potential hazard. This is because OSHA imputes knowledge of managers to your organization. OSHA must prove the following to establish that a standard was violated: (1) the standard applied to the cited condition; (2) the terms of the standard were violated; (3) one or more employees had access to the relevant hazard; and (4) the employer knew or, with the exercise of reasonable diligence, could have known of the presence of the violation. In doing so, OSHA can rely on statements made by the employer’s managers at any time during the inspection. It makes no difference if the manager makes the comment during the opening conference, during the walk-around, during a formal interview or in idle small talk – it can (and will) be used against the employer. 

The compliance officer will inevitably request a list of documents. In most instances, you are only required to provide your OSHA 300 logs within four hours of OSHA requesting them. For all other documents, request a written list of the requested documents and designate one representative to communicate with OSHA regarding your production of documents. This allows you to carefully inspect the list of documents to determine whether the request is reasonable, whether there are any trade secret or privilege concerns in the documents requested, and what documents should be furnished.

Employee Interviews

It is important that both your management and non-management employees understand their rights and are instructed to tell the truth. Non-management employees are not required to participate in OSHA interviews, but if they refuse, OSHA could issue a subpoena at a later date. If the employee agrees to participate, he or she has a right to a private interview without management and also has a right to refuse to be recorded in any fashion. Any union employees may have a union representative present during the interview, as well.

In contrast, management employees have a right to a management representative or counsel during the interview. You also have a right to schedule management employees for a later date, after you have had the opportunity to meet with and prepare the managers. For the reasons discussed above, managers should be prepared in advance for a CSHO interview, should not permit the CSHO to record their interviews in any format, and should not verify or sign off on the CSHO’s notes of the interview. 

Closing Conference

After the CSHO conducts the walk-around, he or she will conduct a closing conference. This is your opportunity to learn what violations the CSHO believes exist at your worksite and why. This is also a time to note any abatement of hazards that was made during the inspection as well as request a copy of any photographs or monitoring results taken by the CSHO.

After the Inspection

If you receive a Citation and Notification of Penalty, you have the right to contest any citation issued to your organization, including the proposed penalties and abatement dates. Just because OSHA issues a citation does not mean your organization has violated the OSH Act. OSHA is required to prove a violation occurred.

Additionally, you should consider the potential impact of simply accepting and paying an OSHA Citation. While OSHA citations are harmful to any employer, some organizations rely on their safety record to win bids and keep premiums down. Even more troubling, an OSHA citation can be used as evidence of negligence in an accompanying liability case against your organization. 

Best Practices

  • If you are able and time permits, have an attorney present during the OSHA inspection to provide most of the information to the OSHA inspector. 
  • Notify any subcontractor or other employers on your worksite that OSHA has arrived.
  • Reasonably limit the scope, time and manner of the inspection.
  • Arrange interviews of management employees at a later date after you have an opportunity to prepare.
  • Refrain from volunteering unnecessary information that may impute knowledge of a hazard on your organization. 

OSHA inspections can be stressful for all involved, but they don’t have to be. Knowing what your rights are and when to assert them will help protect your organization.

Samantha Monsees is an attorney in the Kansas City office of national labor and employment law firm Fisher Phillips. She can be reached at smonsees@fisherphillips.com

This feature appeared in the December 2019 issues of the ACP Magazines:

California Builder & Engineer, Construction, Construction Digest, Construction News, Constructioneer, Dixie Contractor, Michigan Contractor & Builder, Midwest Contractor, New England Construction, Pacific Builder & Engineer, Rocky Mountain Construction, Texas Contractor,
Western Builder

CSDA Announces New Individual Memberships for Operators, Supervisors and Specifiers

 CSDA is pleased to announce three new membership categories specifically designed for individuals in the concrete construction industry. 

These individual memberships were specially tailored to the needs of field personnel, safety managers, operations managers and specifiers, including architects, engineers and general contractors. These new members will benefit from gaining access to a vast library of industry-specific resources, training classes industry news and product updates. 

Each individual membership category will have benefits specific to its members. The Field Personnel category was designed with operators, laborers and field professionals in mind. These members will have access to safety and training resources, product updates, receive discounts on association events and materials and gain the ability to connect with other operators and personnel all over the world. The Operations category includes safety managers, estimators, dispatchers and supervisors. They will have access to a library of over 100 Toolbox Safety Tips (TSTs), a safety resource online database, industry news and discounts on safety materials and training classes. The Specifier category gives architects, engineers, general contractors and government officials a resource to access over 50 specifications, standards and best practices for the concrete renovation industry. They can also request bids from local contractors specific to the job specs and will be able to earn continuing education through CSDA’s partnership with AIA. 

“CSDA recognizes that a company membership may not be the best fit for all of the members of our industry. In order to share our resources to benefit as many as possible, we have created these individual membership categories to enhance the cooperation and information-sharing between contractor companies, operators, manufacturers, specifiers and more,” stated Erin O’Brien, CSDA Executive Director. “Our goal is to grow and expand the member benefits our association offers and this is just the first step in progressing towards this goal.”

These new individual memberships compliment the existing company memberships for contractors, manufacturers, distributors and affiliate. Existing company members can also gain the benefits of these individual memberships at no additional charge. For more information, or to sign up for membership, visit the CSDA website at www.csda.org, contact the CSDA office at 727-577-5004 or email info@csda.org.

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The Concrete Sawing & Drilling Association is a nonprofit trade association of contractors, manufacturers and affiliated members from the construction and renovation industry. Diamond tools for projects requiring sawing, drilling, selective demolition, cutting and polishing offers the construction industry many benefits including lower total project costs, precision cutting, maintenance of structural integrity, reduced downtime, reduced noise, dust and debris, limited access cutting and the ability to cut heavily-reinforced concrete. Founded in 1972, CSDA has 500 member companies worldwide.

CSDA Announces New Executive Director

The Concrete Sawing and Drilling Association (CSDA) is pleased to announce the appointment of Erin O’Brien as its’ next Executive Director, following the retirement of Pat O’Brien who served as Executive Director of the association since 1992.

“Erin has been intimately involved with the operations of CSDA for the past 10 years, so the opportunity to have her become the new Executive Director of the association creates a turnover (transition?) that will be as seamless as can be imagined. This new chapter creates the opportunity for innovation as well as the growth of programs for our members and the industry as we enter a new decade,” according to Matthew Finnigan, CSDA’s President.

O’Brien began her duties as Executive Director on January 1, 2020 and will lead the association’s presence at the World of Concrete in Las Vegas, NV from February 4 – 7, 2020 and at its Annual Convention & Tech Fair in Carlsbad, CA from March 31, April 4, 2020. 

The Concrete Sawing & Drilling Association is a nonprofit trade association of contractors, manufacturers and affiliated members from the construction and renovation industry. Diamond tools for projects requiring sawing, drilling, selective demolition, cutting and polishing offers the construction industry many benefits including lower total project costs, precision cutting, maintenance of structural integrity, reduced downtime, reduced noise, dust and debris, limited access cutting and the ability to cut heavily-reinforced concrete. Founded in 1972, CSDA has 500 member companies worldwide.