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CONTINUING EDUCATION + WAITING WASTE + ACCELERATORS
PRECAST INC.
A Publication of the National Precast Concrete Association | JULY/AUGUST 2020
Flying High
MONARCH PRECAST
CONCRETE CORPORATION
+
INVESTING IN
OUTREACH
BERYLLIUM SAFETY:
The Basics
CONTENTS
J U LY / A U G U S T 2 0 2 0
20
Photo courtesy of Monarch Precast
Flying High:
MONARCH PRECAST CONCRETE CORPORATION
20 Seven decades and two generations in, Monarch Precast is thriving with a focus on
quality products and its employees.
TECHNICALLY SPEAKING WORKING FOR YOU
On the Cover:
5 Questions from the Field 33 Developing Precast Specifications Across the U.S.
Monarch Precast
Concrete 6 A Closer Look: Accelerators & Retarders
Corporation in
INDUSTRY NEWS
Allentown, Pa.,
10 Beryllium Safety: The Basics 34 People & Products
manufactures
a wide array of MANAGEMENT RESOURCES
underground 12 Continuing Education Helps Manufacturers
infrastructure 36 NPCA Calendar
Raise the Bar
products.
36 Advertisers Index
16 Investing in Outreach
Photo courtesy of
Monarch Precast
SUSTAINABILITY
30 The Seven Wastes: Waiting Waste
2 PRECAST INC.
precast.org 3
PRECAST INC.
PUBLISHER
Frederick H. Grubbe, MBA, CAE
EXECUTIVE EDITOR
Kirk Stelsel, CAE
ASSOCIATE EDITOR
Matt Werner
TECHNICAL EDITORS
Eric Carleton, P.E.
Phillip Cutler, P.E.
Claude Goguen, P.E., LEED AP
Kayla Hanson, P.E.
Alex Morales, M.Ed.
GRAPHIC DESIGN
Molly Tippner
ADVERTISING
Brenda C. Ibitz
bibitz@precast.org
(317) 571-9500
Precast Inc. (ISSN 1940-9184 print, ISSN 1940-9192
online) is published bimonthly by NPCA.
Material in this publication may not be reproduced
without written permission from NPCA. Requests for
permission should be directed to the editor.
© 2020 NPCA
Address your letters and comments to the editor:
Precast Inc./Editor
1320 City Center Drive, Suite 200
Carmel, IN 46032
(800) 366-7731
Fax: (317) 571-0041
Email: npca@precast.org
precast.org
NPCA is the trade association representing
manufacturers of industrial plant-produced concrete
products and suppliers to the industry around the world.
CONNECT WITH US
4 PRECAST INC.
TECHNICALLY Speaking
Questions from the Field
Questions from the Field is a selection of questions NPCA Technical Services engineers received from calls, emails and comments on
blog posts or magazine articles posted on precast.org.
If you have a technical question, contact us by calling (800) 366-7731 or visit precast.org/technical-services.
Jerry writes: understood when it comes to cement’s role
in concrete.
The term “hydration” is used
Cement hydration is a chemical reaction.
to describe the loss of water Specifically, it’s an exothermic reaction,
from concrete during the curing meaning that the chemical process
process. My understanding is that produces heat as it progresses. Contrary to
water loss refers to “dehydration” popular belief, water does not evaporate
and water gain to “hydration.” during the cement hydration process.
Rather, it is consumed chemically as the
Does the concrete industry use
exothermic reaction converts the paste
these two terms in reverse? If so,
Photo by Ryan Thorpe / Unsplash
into a hardened mass.1 Because heat is
why? generated by the chemical reaction, water
can reach evaporation temperatures. This
NPCA Technical Services engineers
is why a freshly placed concrete mixture is
answered:
covered until at least initial set, and often
This is a great question. In everyday longer. Precast concrete producers seek to
Terry writes:
use, hydration is generally understood as prevent the evaporation of water, because
“water gain.” Dictionary.com specifically water released into the atmosphere is then During a discussion with a
defines hydration as “the process of causing unavailable to continue to hydrate cement. homebuilder about our driveway
something to absorb water” and uses the Producing concrete in the plant allows slab and curing time, he said he
following sentence as an example: “The for better control of moisture loss during the had heard the Hoover Dam is still
human body requires adequate hydration early life of freshly placed concrete and is
to function properly.” But in chemistry,
curing. Is that possible, given the
one of the many reasons precast producers
hydration is defined as “the process of can manufacture products of more consistent
time that has elapsed since its
combining a substance chemically with quality than cast-in-place alternatives. construction?
water molecules.” This is how the term is
NPCA Technical Services engineers
answered:
Yes, it’s possible. A common adage in the
concrete industry is that the Hoover Dam
is stronger today than it was yesterday. The
hydration process continues in perpetuity
if both water and un-hydrated cement are
present, helping concrete to continually gain
strength over time. The Hoover Dam was
a gigantic concrete pour and if additional
curing is occurring it would be deep
within its mass. However, it is likely that
additional strength gain after many years
is infinitesimally small and thus difficult to
quantify. PI
REFERENCES:
1 https://precast.org/2016/03/cement-hydration-kinetics
NPCA file photo
precast.org 5
TECHNICALLY Speaking
A Closer Look:
ACCELERATORS
& RETARDERS
NPCA file photo
Thanks to a wide variety of available admixtures, precast concrete producers
can manufacture durable, high-quality products for nearly any project or need.
By Claude Goguen, P.E., LEED AP
Editor’s Note: This is the fourth article in a year-long series explaining common raw materials used in precast.
S
ometimes as humans we seek to slow things down, like the The setting of concrete can be described with many terms, including
final days of a vacation. But speeding things up can also be hardening, drying, stiffening and more. However, these terms are not
preferable, like the time spent sitting in the dentist’s chair. synonymous. To help clear up some of the confusion, it’s best to start
Manufacturing concrete also requires variations in speed. with the basics.
Hot and cold weather concreting, avoiding cold joints between lifts, When cement and water are mixed, hydration occurs. Hydration
countering the effects of supplementary cementitious materials (SCMs) is the chemical reaction that takes place when water is added to
and admixtures, and facilitating double pours are some of the situations a hydraulic cementitious material. Many factors affect the rate of
that necessitate admixtures that can either slow down or speed up hydration, which in turn will affect setting time and strength gain.
production processes. Setting is defined as the process of hydrated cement (paste) changing
6 PRECAST INC.
Hydration is from a fluid state to a solid state. mainly CSH. Whereas the C4AF contributes little to set and strength
According to the American Concrete
the chemical Institute (ACI), initial set is a “degree
gain.
reaction that of stiffening of a cementitious mixture THE FIVE STEPS OF HYDRATION
takes place when less than final set, generally stated as When a cement particle meets water, the hydration reaction begins
water is added an empirical value indicating the time on its journey to creating a solid product. Hydration can be split up
required for the cementitious mixture
to a hydraulic to stiffen sufficiently to resist, to an
into five phases. The first 10-20 minutes of the reaction is called the
pre-induction period. Here, early reactions of the C3S and C3A in the
cementitious established degree, the penetration cement produce calcium, silicate and aluminate ions, and the water
material. of a weighted test device.” Final set becomes a pore solution. During this phase, the C3A reaction also
is defined by ACI as a “degree of releases a significant amount of heat.
stiffening of a cementitious mixture Everything slows down in the next phase, which is the induction
greater than initial setting, generally stated as an empirical value or dormant period. At this point, the concrete remains fluid and can
indicating the time required for the cementitious mixture to stiffen still be placed. Varying theories exist surrounding what influences the
sufficiently to resist, to an established degree, the penetration of a length of the induction period.
weighted test device.” The device they are referring to is most often the “The cement minerals are very soluble and keep releasing ions into
Vicat needle that is described in ASTM C403 – Standard Test Method the pore solution,” said Jeff Thomas, senior principal scientist with
for Time of Setting of Concrete Mixtures by Penetration Resistance. GCP Applied Technologies. “Eventually it becomes supersaturated
Hardening, or strength development during hydration, is related to and solid hydration products such as calcium hydroxide and calcium-
the formation of a few constituents which consist of mainly calcium silicate-hydrate nucleate and begin to grow. This then frees up space
silicate hydrate (CSH) and calcium hydroxide (CH). This process binds for more ions in the pore solution and the process continues.
the aggregates together to increase the stress-bearing capacity of the “The hydration products tend to form on top of the dissolving
concrete. This is different than setting because it involves the concrete cement grains, eventually forming a layer around them. Since these
as a whole including the aggregate – not just the paste. Slump loss, solid products occupy more space than the original cementitious
or spread loss, is the reduction of workability that occurs as concrete material, the cement grains actually grow in size as they react.”
naturally sets. Eventually, the hydrated product of several cement grains will
Some of these terms may sound similar, but there are situations connect and form a solid network. This is when setting begins.
when a manufacturer may want to increase strength gain while Next, the dormant period gives way to the third accelerated phase of
maintaining usual set times, or vice versa. There are also instances hydration. The C3S in the cement continues to react, and the concrete
where manufacturers might want to pause the hydration process gains strength as CSH continues to form. The release of heat rises again
to allow for the concrete to be placed during an extended pour. but then falls during the fourth stage, which is commonly referred to
Admixtures are available to suit all these purposes. Below, we will as the deceleration period despite early strength gain still progressing
discuss set-controlling admixtures along with hydration modifiers. considerably. The final stage is a slow, continuous hydration period that
contributes to later strength gain.
CEMENT PARTICLES The amount of time needed for each phase depends on many factors,
The chemical components of cement affect concrete performance. such as: temperature; type of cement; w/c; presence of SCMs; and use
When it is manufactured, four main components (phases) are present of admixtures.
in the final cement product: dicalcium silicate (C2S), tricalcium silicate
(C3S), tricalcium aluminate (C3A) and tetracalcium aluminoferrite ACCELERATORS
(C4AF). Accelerating admixtures work to reduce the induction or dormant
C3S is more soluble than C2S and therefore hydrates rapidly. It is the period of hydration. Precasters’ productivity depends on how
main influencer on initial set and initial strength gain and produces quickly forms can be turned over while still allowing the concrete to
desirable CSH and CH in the concrete. C3A is the more soluble phase gain essential hardened qualities. Accelerating admixtures, which
in cement and, while it greatly impacts initial set, it does not produce are designated as Type C admixtures under ASTM C494 / C494M
CSH or CH during hydration. Consequently, cement plants add Standard Specification for Chemical Admixtures for Concrete, help
gypsum to temper the rapid hardening effects of the C3A. C2S reacts expedite the process. Chloride accelerators are not recommended
slower and contributes to longer-term strength development producing in steel reinforced concrete due to a risk of accelerated corrosion to
THE FIVE PHASES OF CEMENT HYDRATION
PHASE 1 PHASE 2 PHASE 3 PHASE 4 PHASE 5
Pre-Induction Induction Acceleration Deceleration Continued
Period Period Period Period Hydration Period
precast.org 7
NPCA file photo
With proper
quality production
practices, long-term
strengths should
When casting large products such as bridge beams, a set
still be equivalent retarder may be used to avoid cold joints.
or higher than the
same concrete
made without a the steel. Several non-chloride or higher than the same concrete made without a retarder. Most set
accelerators are available for retarders will also act as a water reducer.
retarder. use in concrete. Many different
formulations exist, but they mainly HYDRATION STABILIZERS
consist of organic compounds or inorganic salts. The technology behind hydration stabilizers has advanced
Inorganic salts can consist of sodium and calcium salts of formate, significantly in recent years, allowing them to essentially become
nitrate and thiocyanate. Calcium nitrates are commonly used in the retarders on steroids. These powerful stabilizers suspend the hydration
precast industry. Organic compounds include triethanolamine (TEA), of cement for extended periods of time.
which can be used on its own or mixed in a formulation of water “Typical set retarders are harder to predict,” Marc Sinicrope, director
reducers. Typically, accelerating admixtures are customized to fulfill of technology at Master Builders (formally BASF), said. “But hydration
a specific need in the presence of the type and quantity of cement stabilizers are more predictable and useful in certain situations. For
used. Some have accelerating and water-reducing properties (Type E example, some cements may have very high C3A levels, which can
admixtures), while some are only accelerators (Type C admixtures). accelerate set – hydration stabilizers can hold off slump loss until the
concrete is placed, giving the precaster more working time.”
RETARDERS Hydration stabilizers can be categorized as Type B retarding and/or
To slow down setting time, precasters use a retarding admixture. Type D water-reducing admixtures under ASTM C494. Depending on
Some precasters may remember the days when sugar was added to the how the hydration stabilizer is used, it’s impact on long-term strength
concrete mixture to slow down set. Sugar and other forms of sucrose would range from no impact to an increase similar to that obtained by
– such as corn syrup – along with hydroxylated carboxylic acids or using a conventional retarder.
their salts, and lignosulfonates are used predominantly in concrete set
reducers. These admixtures are designated as Type B under ASTM WORKABILITY-RETAINING ADMIXTURES
C494 and can be applied to form surfaces or added to the mix to delay To help maintain slump or spread, workability-retaining admixtures
the set of paste from just a short time to several hours. are effective. These admixtures do not retard set or significantly affect
Retarders work to extend the period in which the concrete remains early-age strength gain, which can be especially beneficial when using
plastic. They reduce the chemical reaction speed by slowing the self-consolidating concrete. Workability-retaining admixtures are
dissolution of the cement phases and inhibiting the nucleation of CSH. classified as Type S under ASTM C494 and are typically formulated
Lignosulfonates, for example, work by adsorbing to the C3S and C3A with polymers.
and forming a coating that slows down its dissolution. This results
in slowing set and in lower early strength gain. With proper quality NEW TECHNOLOGIES
production practices, long-term strengths should still be equivalent Various evolving technologies, many linked to nanotechnology, are
resulting in new products that can affect setting, hydration, strength
8 PRECAST INC.gain and workability. One such technology involves using seeding
crystals to provide nucleation sites for hydration products. Recently
introduced to the North American market is a product that uses CSH
seeds.
Nanoparticles consisting of synthetically produced crystalline CSH
are added to provide sites for nucleation of hydrated product. This
results in early and late strength gain due to improved hydration. The
addition of nucleation sites is referred to as “seeding” and is showing
promising results in many studies.1 The use of CSH seeds can also
reportedly permit reductions in total cementitious content, which can
contribute to a lower environmental impact.
SPEEDING UP TO SLOW DOWN
Thanks to the many admixture suppliers to the industry, precasters
have access to a wide assortment of amazing products that can fit
any condition, resulting in a high-quality product. Some may avoid
considering the use of these products for fear of increasing initial costs
per yard, but a consultation with an admixture specialist may reveal that
that the long-term costs and benefits outweigh the initial investment. PI
Claude Goguen, P.E., LEED AP, is NPCA’s director of technical education and
outreach.
REFERENCES:
1 Influence of Nucleation Seeding on the Compressive Strength of Ordinary Portland Cement and Alkali Activated
Blast Furnace Slag - https://rosap.ntl.bts.gov/view/dot/35152/dot_35152_DS1.pdf?
2 https://www.zkg.de/en/artikel/zkg_The_acceleration_of_cement_hydration_by_seeding_influence_of_the_cement_1579652.html
precast.org 9TECHNICALLY Speaking
Beryllium
Safety:
THE BASICS
There are several steps precasters
must take to protect workers from
beryllium exposure and comply with
OSHA’s final rule.
By Mason Nichols
I
n 2018, the Occupational Safety and Health Administration began
enforcing a new permissible exposure limit (PEL) for crystalline
silica.1 The revised limit was well publicized as it halved the
PEL from 100 micrograms per cubic meter (μg/m3) to 50 μg/m3.
However, an equally important OSHA final rule also went into effect in
2018 with less fanfare.
Beryllium, a lightweight metal that is most often used in the
aerospace, electronics, energy and telecommunications industries, is
also present in precast concrete operations.2 At a precast plant, multiple
steps in the production process can lead to beryllium exposure. OSHA’s
final rule reduces the PEL for beryllium by a factor of ten, from 2 μg/
m3 to just 0.2 μg/m3, meaning it’s imperative for precast producers to
understand both the operations that can lead to exposure as well as the
steps to mitigate or eliminate the issue.
EXPOSURE AND HEALTH EFFECTS
According to Paul Mellon, director of government and regulatory
affairs at Strategic Materials, abrasive blasting is the primary source of
potential beryllium exposure at precast plants. Typically, this type of
abrasive blasting is used to achieve a specific surface texture, such as on
a wall panel or other above-ground piece.
However, any time abrasive blasting is performed, including blasting
operations used for cleaning forms, the issue can arise. Exposure to
trace levels of beryllium is also possible via other work performed at the
plant, including welding.
Mellon has worked on the beryllium issue directly with OSHA for
more than a decade and is considered the NPCA Safety Committee’s
10 PRECAST INC.subject matter expert. Mellon shared that according the process to disperse more readily, significantly
to OSHA and safety data sheets, there are two known lowering the danger for both the worker performing the
materials commonly used in abrasive blasting that blasting and the cleanup crew. Providing or enhancing
contain beryllium – coal slag and copper slag. When ventilation systems is also effective.
either of these materials is used, special considerations “We conducted beryllium air sampling with industrial
must be made, as “high dust conditions inherent in hygienists for our welders a few years ago and were
abrasive blasting operations” may expose workers to below the PEL,” said Ruben Gallegos, environmental
dangerous levels.3 The following are the key provisions health and safety manager for Jensen Precast in Fontana,
of the beryllium final rule: Calif. “Nonetheless, our welders have fume extractor
systems at the point of operation as well as mechanical
• Establishes new, lower permissible exposure limit for ventilation.”
beryllium of 0.2 μg/m3, averaged over 8 hours. Gallegos added that Jensen Precast’s rebar welders
• Establishes new, short-term exposure limit for beryllium of also work outside, where there is ample natural
2.0 μg/m3, over a 15-minute sampling period. ventilation.
To further bolster worker protection, respirators
• Requires employers to use engineering and work practice
controls (such as ventilation or enclosure) to limit worker can be used. According to Mellon, a form of standard
exposure to beryllium, provide respirators when controls protection for workers who are blasting is a blast hood,
cannot adequately limit exposure, limit worker access to which has an assigned protection factor (APF)6 of 1,000
high-exposure areas, develop a written exposure control plan, from the National Institute of Occupational Safety and
and train workers on beryllium hazards. Health (NIOSH). But for members of the cleanup crew
or individuals working in tight quarters, a recent change
• Requires employers to make available medical exams to should be noted.
monitor exposed workers and provides medical removal
“Last summer, due to the beryllium rule coming
protection benefits to workers with a beryllium-related
out, NIOSH made a change in their recommendation
disease.4
for individuals who may be at or near the exposure
limit,” Mellon said. “They are now calling for full-face
While the reduced PEL is currently in effect, the respirators. That’s a big difference, because even with
engineering controls portion of the rule remains in crystalline silica, NIOSH doesn’t require them.”
development. When complete, this part of the rule will The dangers associated with beryllium – as well as the
identify specific approaches, such as ventilation or the means by which it can enter the body – both contribute
use of an enclosure, to limit worker exposure. to the call for more stringent Personal Protective
For precast plants that do not take the appropriate Equipment (PPE). Unlike crystalline silica, beryllium
measures to mitigate or eliminate exposure to beryllium, that contacts a worker’s eyes or skin can potentially lead
dire consequences may follow. OSHA states that to sensitivity and eventually result in illness. This leads
“inhaling or contacting beryllium can cause an immune to the need for full-face respirators along with proper
response that results in an individual being sensitized” protection for the face and any exposed skin.
to the material. Those who exhibit this sensitization are
then at risk for developing chronic beryllium disease COMPLIANCE IS KEY
(CBD), a serious pulmonary illness that could lead to Because the PELs for beryllium and crystalline
death. Workers may also suffer from acute beryllium silica are measured on the same scale, it’s easy to see
disease, which is a form of chemical pneumonia, or lung just how dangerous exposure to beryllium can be
cancer. when comparing the two final rules. The difference
between 50 μg/m3 and 0.2 μg/m3 is significant, further
ADDRESSING THE ISSUE emphasizing the need for precasters to identify potential
OSHA’s primary method for handling any safety exposures to beryllium and effectively mitigate or
hazard comes directly from its hierarchy of controls.5 eliminate them according to the provisions of the final
When it comes to beryllium, elimination or substitution rule. Thankfully, there are many steps that can be taken
remains the most effective approach control. to remain in compliance. PI
In situations where coal slag or copper slag is used,
additional methods exist for Mason Nichols is a Grand Rapids, Mich.-based writer and editor
who has covered the precast concrete industry since 2013.
ensuring the safety of team
members and staying below the REFERENCES:
Safety precautions
such as proper PEL. One of the most effective 1 https://precast.org/2018/09/silica-rule-enforcement-has-begun/
PPE ensure approaches is conducting 2 https://www.osha.gov/Publications/OSHA3821.pdf
employees 3 https://www.osha.gov/SLTC/beryllium/
abrasive blasting operations
remain safe 4 https://www.osha.gov/berylliumrule/index.html
during blasting outdoors. This allows the dust 5 https://www.osha.gov/shpguidelines/hazard-prevention.html
operations. and particles created during 6 https://www.osha.gov/Publications/3352-APF-respirators.pdf
precast.org 11MANAGEMENT
During Precast
University courses,
students participate
in group activities
that drive the
NPCA file photo
lessons home.
Continuing Education Helps Manufacturers
Raise the Bar
I
By providing workplace professional t would be hard to argue with the value of lifelong learning. Whether
the goal is to update skills for a specific job, prepare someone for
development opportunities, precast a new position or develop a personal interest, the time and effort
results in enhanced skills, an expanded knowledge base and greater
concrete manufacturers can help personal capabilities. This translates into real gains in the manufacturing
reduce employee turnover, improve environment, where both employees and employers experience the
benefits.
loyalty and enhance the career According to the Society for Human Resource Management (SHRM),
51% of companies offer undergraduate educational assistance and 49%
paths of valued team members. provide graduate educational assistance.1 Beyond formal education
options, many companies offer training courses, online educational
opportunities, certification courses and other ways for their workers to
By Bridget McCrea
continue their lifelong learning journeys.
12 PRECAST INC.For employees, continuing education can help fill skills and
knowledge gaps, provide information about industry advancements,
encourage exploration of new career directions, and polish
their resumes for future opportunities. For precasters that offer
continuing education opportunities, the rewards come in the form
of heightened employee engagement, improved loyalty, better
retention and less turnover.
FILLING IN THE SKILLS GAPS
Whether it’s a recent college grad, a long-time employee or a
new executive, everyone can use a little extra education during his
or her career. A Texas A&M University study uncovered a growing
need for skilled workers in the area of advanced manufacturing,
including the use of new technologies and advanced processes to
manufacture products of high value.2 The report’s authors note that
U.S. government employment data reveals a lack of skilled workers
in the manufacturing sector. Additionally, there is concern over the
job-readiness of college graduates and the potential gaps in skill
sets needed to be successful in an industrial setting, especially in the
fields of engineering and manufacturing.
At Panhandle Concrete Products in Scottsbluff, Neb., Andrew
Hayward, quality and production manager, said the company offers
a variety of continuing education opportunities for staff members.
The company uses online webinars, meetings and short video clips
to help keep employees up to speed on the most important changes
in precast processes, industry trends and customer preferences.
“We get everyone together in one room, show the videos and then
talk together as a group about the topic at hand,” said Hayward, who
pauses the presentations at certain points to explain specific topics
and brainstorm ideas with the group. “I talk to our employees about
their experiences and discuss how this new information and/or the
process changes can be applied at our company.”
Hayward added that he often turns to educational offerings
from the National Precast Concrete Association to round out
Panhandle’s continuing education program. Most recently, he used
the organization’s content across four different production/safety
meetings. He especially enjoys having a large catalogue of online
options at his fingertips so they can log on and get the information
into practice right away.
Hayward loves NPCA’s short, how-to videos, which serve as
Precast University classes provide students with knowledge that enhances their
careers and benefits their employers.
NPCA file photo
precast.org 13a refresher for workers who need bite-sized chunks of continuing To administer its continuing education, Panhandle makes time during
education. Featuring topics like applying form oil or consolidating company hours – especially on slower days – for employees to attend
concrete, the clips can be quickly accessed on an as-needed basis. Precast University3 and work on their Master Precaster coursework.
“It’s always good to go back every six months or so and get a Currently, three staff members have graduated from the program
refresher,” said Hayward, whose team also attends NPCA webinars. and a handful of others are working through the program. In return,
“The options range from broad topics for entry-level employees to very Panhandle gets a workforce that’s continually evolving and learning.
technical topics for veteran workers.” “It’s important to keep on top of the trends and new specifications in
the industry,” Hayward said. “We want our employees to know what’s
out there, whether it’s a new piece of equipment or a new way to build
something. It helps them stay sharp and keeps us ahead of the game.”
WALKING THE WALK
NPCA member Rosetta Hardscapes of Charlevoix, Mich., highly
values continuing education on numerous fronts. The company creates
webinars for producers, many of which require help working through
common challenges.
“We developed a job costing webinar and sent it out to our entire
network,” said Rosetta Hardscapes Operations Specialist Aaron Ausen.
“We had about 30 executives and sales professionals come to learn best
practices on how to cost our products, which showed us that this was
NPCA file photo
a real issue that attendees needed help with. I’m a big believer in well-
rounded continuing education.
Andy Hayward of Panhandle Concrete Products not only encourages his employees “(NPCA does) a phenomenal job at not just pulling in business and
to participate in continuing education, he also leads by example and completed the
Precast University coursework himself and became a Master Precaster at The Precast
industry experts, but giving attendees the chance to learn from other
Show 2020. folks who have actually ‘walked the walk.’”
14 PRECAST INC.MEETING YOUNGER GENERATIONS HALFWAY
As younger generations of workers make their way into the
precast industry, most are looking for different benefits, perks
and job experiences. Generations Y and Z both gravitate toward
companies that offer ample workplace development opportunities.
The proof is in the numbers. According to
PricewaterhouseCoopers, the biggest draw for millennials in the
workplace is the opportunity for progression (52% of millennials
surveyed say this makes an employer an attractive prospect).4
Asked which benefits they would most value from an employer,
millennials named training and development and flexible working
opportunities over financial benefits.
NPCA Vice President of Technical Services and Professional
Development Marti Harrell said these and other realities should
prompt more manufacturers to develop new or enhance existing
continuing education offerings.
“Precasters have to meet these younger generations halfway, and
one great way to do that is by giving them expanded educational
opportunities,” she said.
Leadership NPCA is a good starting point for precasters looking
to follow Harrell’s advice.5 Meant to sharpen students’ skills and
abilities by providing management training, industry association
experience and networking opportunities that are vital to
successful leadership, LNPCA accepts up to 12 students per year in
order to provide meaningful, small-group learning opportunities
that will last throughout the participants’ careers. NPCA also offers
free “Precast Learning Lab” videos consisting of 5- to 10-minute
best practice discussions on specific production practices, sales
techniques and marketing approaches.6
Precast University is another option and companies will soon
be able to leverage a new onboarding webinar series, which covers
everything a new hire needs to know when he or she begins their
work.
“This will help employees get up to speed very quickly and is
particularly relevant for younger generations that may not choose
post-secondary education but are already familiar with online
learning,” Harrell said.
Harrell reminds manufacturers that continuing education can
be as simple as playing a short video on safety practices or on a
new production concept during weekly, 15-minute team huddles.
In other words, it doesn’t take a year-long, formal course to make
employees realize that you’re willing to invest in their personal and
professional development.
In the end, the investment is a win-win as employee
development not only benefits the employee as they advance their
career, but it helps your company succeed in the future. PI
Bridget McCrea is a freelance writer who covers manufacturing, industry
and technology. She is a winner of the Florida Magazine Association’s
Gold Award for best trade-technical feature statewide.
REFERENCES:
1 https://www.shrm.org/hr-today/news/hr-magazine/spring2019/pages/education-benefits-present-
learning-opportunity.aspx
2 https://peer.asee.org/board-76-bridging-the-workforce-skills-gap-in-high-value-manufacturing-through-
continuing-education
3 https://precast.org/precastuniversity
4 https://www.pwc.com/co/es/publicaciones/assets/millennials-at-work.pdf
5 https://precast.org/education/npca-leadership-academy/leadershipnpca
6 https://precast.org/learning-lab
precast.org 15MANAGEMENT
Investing in
OUTREACH
Connecting with
W
hen businesses in the precast industry talk about outreach, the focus is often on
connecting with local specifiers, contractors and engineers. But what if there was
future specifiers a way to educate these groups on the benefits of precast concrete before they even
enter the workforce?
and engineers The NPCA Foundation provides scholarships as one way to expose students to the precast
industry, but design studios and precast-specific courses have added a new dynamic to bringing
can help grow precast to the classroom.
your business. WORD SPREADS
US Formliner General Manager Ray Clark knew he was onto something years ago after teaching
architectural students about the precast concrete industry at Clemson University. He could tell they
By Matt Werner were excited about meeting a professional in the field and learning more about the material.
16 PRECAST INC.Photo courtesy of Mustafa Mashal and Idaho State University
“I was driving home, and I just thought, ‘Wow. This is our future,’” Clark said. “These
are the people designing our products, and we have to do more of this.”
Soon, other universities and colleges began reaching out, seeking someone to speak at
their classes.
“We’re seeing engineering students being exposed to precast concrete that otherwise
never would have been exposed,” Clark said. “We’re hearing from the professors that
had these things not come along, these students never would’ve learned about precast.
To me, that’s shocking, and we have to educate the students who are going to be
specifying our products one day.”
BENEFITS FOR ALL SIDES
No matter where he is presenting, Clark can tell students are starved for more
information about precast.
“The questions they ask are sometimes questions professionals don’t even ask,” he
noted. “They’ll ask something that makes me think more critically.”
He’s also seen the benefits of engaging with the people who will one day be specifying
precast.
“We’ve seen these students call up their professors and say, ‘Hey, I remember taking that
class, but I need help. I’m trying to convince one of our senior designers to go precast,’” Clark
explained. “That’s powerful. It doesn’t get any better than that.”
Photo courtesy of Mustafa Mashal and Idaho State University
Ray Clark of Mustafa Mashal, Ph.D., P.E., SECB, CPEng, IntPE(NZ), is an
US Formliner
uses hands-on associate professor in the department of civil and environmental
activities with engineering at Idaho State University, where the NPCA Foundation,
Idaho State in conjunction with the PCI Foundation, recently helped sponsor
students to
bring to life what a precast design studio. The biggest benefit for his students is the
he teaches. chance to learn about real-life projects and hear from professionals in
precast.org 17the field to understand the benefits of precast concrete. Clark knows it can be tough for small companies, particularly those
“I get to learn about the trends and the state-of-the-art technologies as busy as precast concrete manufacturers, but said you don’t have to
in the industry,” he said. “I get to know what topics are important to be actively participate in everything. Instead, he encourages individuals
covered during the class so that, upon graduation, the students already to go by a university or college and drop off some literature or offer to
have some exposure and knowledge of those topics when they join the teach one class.
industry.” “It’s an investment, but it’s a long-term investment
Mashal said outreach from the precast industry that will eventually pay off,” he said.
“A strong
has enhanced the material’s visibility within ISU’s Mashal also encouraged others in the industry to
civil and environmental engineering program. It has partnership perform outreach, as there are many students who stand
encouraged his students to participate in the precast between academia to benefit.
concrete competitions and research projects and “These students will be the future of the industry,”
and industry will
students signed up for NPCA and PCI memberships. he said. “I have seen how a lecture by someone from
Some students were even motivated to consider a contribute to the industry can inspire students. A strong partnership
career in precast concrete upon graduation. student success between academia and industry will contribute to
student success and service to the precast concrete
and service to the
LONG-TERM INVESTMENT industry.”
Precast concrete producers must compete with precast concrete Clark has seen the benefits for his company,
a slew of alternative materials in the construction industry.” customers and students from his outreach efforts at
industry. Reaching the people who will one day be colleges and universities.
– Ray Clark, US Formliner
specifying these materials creates an advantage. “If you lay the groundwork now, the rewards will
“If you’re so focused on hanging on to what you’ve come,” Clark said. “It’s right there in front of us.” PI
got and not interested in other things, that’s fine, but then you’re not
Matt Werner is the managing editor of Precast Solutions magazine and is NPCA’s
investing in the future,” Clark explained. “Those that invest in the
communication manager.
future get the biggest returns on the investment.”
18 PRECAST INC.precast.org 19
COVER Feature
Flying
High
MONARCH PRECAST
CONCRETE CORPORATION
Seven decades and two generations in,
Monarch Precast is thriving with a focus on
quality products and its employees.
By Kirk Stelsel, CAE
Photos courtesy of Monarch Precast Concrete Corporation
20 PRECAST INC.W
hen the world emerged from the chaos of
World War II in 1945, it was a markedly
different place. Some countries found
themselves rebuilding both physically and
economically, while others were adjusting
to redrawn borders or finding their way as
newly sovereign nations.
But in the U.S., things were looking up.
The post-war economy was humming and
veterans were putting down roots. One of
those veterans, Paul Stein Sr., did exactly
that in 1949, moving 90 miles from a small town
outside of York, Pa., to the Lehigh Valley to start a
small business.
Monarch Precast Concrete Corporation in
Allentown, Pa., is now run by Paul Sr.’s son, Paul Jr.
The company celebrated 70 years in business in 2019.
SMALL SHOP, BIG THINKING
According to Paul Jr., his dad was self-taught with
an “engineering mind.” Although he did not have
formal education beyond high school, he learned
through reading and experience. In fact, Paul Jr.
recently came across a set of small engineering books
dating back to the ‘50s that belonged to his father.
The construction and concrete industries were not
foreign to Paul Sr. After the war, he worked for his
brother-in-law as a masonry contractor, and his wife’s
relatives were already producing concrete septic
tanks near York. However, it was now up to him to
succeed on his own.
Early on, he was a one-man show, casting and
delivering 360-gallon septic tanks by himself. The
family – mom, dad, grandma and three kids – lived in
a two-bedroom apartment above the shop, so home
was where the heart – and the company – were.
Over time, Paul Sr. added employees and an
outdoor crane, and in the ‘60s he purchased a vacant
plant complete with aggregate bins and a mixer. As
Paul Jr. thinks back on what his father accomplished
in the first few decades, it’s not only the hard work
that stands out, but also his dad’s ingenuity. For
example, in the ‘60s, manholes were an in-demand
product line as municipalities shifted to central
sewage.
“He started dry-casting manholes,” Paul Jr. said.
“He was pretty innovative because nobody else in the
area was doing that.”
Monarch Precast built its current
plant in 2003 to meet increasing
demand and has continued that
growth pattern.
precast.org 21Monarch Precast owner Paul Stein
sees potential in each employee and
empowers them to grow and learn.
Custom products such as this
riser for a force main vault are
a specialty of Monarch Precast
and a source of great pride.
22 PRECAST INC.TOGETHER IS BETTER
In addition to equipment and product lines, two key additions were
Paul Jr. and his younger brother, John. Paul Jr. had worked summers
in high school and joined the company full time in 1974 right after
graduating from college with an engineering degree. By that time, the
company had grown to nearly 30 employees.
He loved working with his dad, who was happy to consider any
idea and either encourage it or gently redirect. Together with the
employees, the three continued to expand the company’s product lines
and customer base. But when the time came to pass the torch, Paul Sr.
didn’t hesitate.
“My dad rounded up my brother and me, and we went up into the
Pocono Mountains to see a job,” Paul Jr. said. “We stopped for lunch, This custom filter box features Fabco
filters and a stainless steel filter table.
and that’s when my dad made the announcement that he was retiring.
I remember the feeling – it was a little bit of a shock, and it was a little
surprising.” with the company in a secretarial role 37 years ago and now holds a
There was plenty of carryover as Paul Sr. kept an office and still leading role in daily operations.
came around every day, albeit with limited hours. In addition, his “Jill, Joe, and Charles are three of the most dedicated, hard-working
tradition of retaining long-term employees is still thriving today. people I have ever met,” said Paul Jr. “That is just to name a few. I
There’s Charles Dixon, who Paul Sr. hired in the ‘70s and is still am very fortunate and proud to have so many dedicated long-term
driving trucks, and Joe Penchishen, who Paul Jr. says is “one of a kind” employees.”
and has been with the company for 50-plus years. Jill Kratzer started Perhaps the most well-known employee in National Precast
precast.org 23Concrete Association circles is Eric Lasko, a Master Precaster and
Leadership NPCA graduate.
“When I started here in 1998, I was young, freshly married and didn’t
know what I wanted to do,” Lasko said. “I didn’t really know about
precast, but once I got into it, I loved it. Every day, it forces you to be at
the top of your game, and there’s not a day that I think I don’t want to be
doing what I’m doing.”
While straightforward in methodology, Paul Jr.’s employee philosophy
is admirable in practice. His focus is on listening to people and giving
them the opportunity to grow along with the company.
From Lasko’s perspective, it all comes down to respect and
communication. He said Paul Jr. has emphasized that the way you
communicate with someone makes a big difference. Just as Paul Sr.
allowed his son to bring any idea to the table, Paul Jr. tells his people
there is no such thing as a bad idea.
“I have a great mentor in Paul,” he said. “As I look at our employees
here, everyone is treated with respect for what they bring to the table. I
think that’s why we have the long-term dedication we do.”
A Precaster’s
Perspective
Having graduated from both NPCA’s Production and Quality
School and Leadership NPCA program, Monarch Precast "I didn’t really know about precast, but
Corporation employee Eric Lasko has a unique perspective on how once I got into it, I loved it. Every day, it
the association has helped him grow in his career. According to forces you to be at the top of your game,
Lasko:
and there’s not a day that I think I don’t
“Upon completion of the Master Precaster and Leadership NPCA
Programs, I achieved a greater perspective as to what is involved in
want to be doing what I’m doing.”
the design and manufacturing process, and it gave me the ability to – Eric Lasko, Monarch Precast; NPCA Master Precaster &
effectively coach our employees both in the QC department and the Leadership NPCA Graduate
plant to produce the best products for our customers.”
COMMON BONDS
Another constant that has been with Monarch Precast
Eric Lasko (left) is a Master
Precaster and Leadership for decades is NPCA. According to Paul Jr., his mom
NPCA graduate. and dad would go to the Conventions and were always
enthused about the great people. Paul Jr.’s first meeting
was in the fall of 1974.
“I remember my very first Convention, and there was
just a world of knowledge right at our fingertips,” Paul.
Jr. said. “It could have been a simple matter like a buckle
on a form or seeing information that I wasn’t even aware
existed.”
Today, the tradition has been passed along to other
Monarch employees. Lasko has been to many Precast
Shows and has built his own network. He said after a year
or two, people know him by face, and soon enough, he
earned lifelong friendships.
“To me, it’s still a family-oriented industry,” he said.
24 PRECAST INC.Antimicrobial Crystalline Technology
For maximum protection
of concrete in severe
sewage conditions
Electron Microscope Images are the property
and copyright of Xypex Chemical Corporation.
Concrete Xypex Crystallization Xypex Crystallization
(Untreated) (Initiated) (Mature)
Xypex Bio-San C500 is a uniquely designed admixture for
integral, long-term protection of concrete in harsh sewage
“That’s really what’s made this industry unique – that we can
conditions with high levels of H2S that cause microbial induced
corrosion. Bio-San C500 combines potent antimicrobial protection
have those relationships.” along with the unique crystalline technology of the Xypex Admix
Paul Jr. could not be more pleased with the relationships C-Series. Bio-San C500 prevents microbial induced corrosion, stops
and knowledge transfer. Lasko was the company’s first infiltration/exfiltration of water, and provides acid and sulphate
Master Precaster and another is on the way. It ties back to his resistance, significantly extending the service life of concrete
philosophy of giving his employees the opportunity to grow sewage collection systems and waste water infrastructure.
alongside the company.
“I just see the potential with every one of them,” Paul Jr. said.
“I’d be neglectful not to nurture their interest in precast and 1.800.961.4477
their desire to learn. It’s refreshing to me that people take that xypex.com
kind of interest in their education. “That education and what
they bring back to help the company is invaluable.”
precast.org 25THINKING AHEAD
Today, Monarch Precast is thriving. In 2003, the company built a plant based on growth-
minded decisions. Manholes and other products manufactured at Monarch Precast can
weigh as much as 60,000 pounds per piece, and the new plant has the cranes to handle
them. The company’s mindset is, “We can tackle just about anything that’s transportable.”
The company has also made a name for itself in the specialty products arena. With an
in-house engineer and a knowledgeable and experienced team both in the office and in
the plant, Monarch Precast manufactures packaged pumping stations, packaged water
meter chambers and a variety of custom products. Paul Jr. also increased the company’s
capabilities in the custom market by switching from steel panel forms to aluminum.
“The weight aspect for the employees is much less strenuous,” he said. “It was in the
interest of safety, productivity and quality. Every year we’re adding some new forms, and a
few years ago, we had a job so custom that Precise Forms made some one-off forms just for
that specific job.”
Another major emphasis is quality control, which has long been a top priority for the
company. Paul Jr. said some of the critical factors were batching and mixing.
“Our team of dedicated employees realizes the emphasis we put
on quality, and they understand the value of customer service.”
– Paul Stein Jr., Monarch Precast
26 PRECAST INC.“We put a brand-new batch plant in that is Monarch
Precast provides
state-of-the-art,” he said. “Back in the ‘70s, my
customers
dad replaced our mixer with a TEKA mixer, with complete
and when we put the new plant up, we put in a solutions such as
this “pre-piped”
larger TEKA mixer because they are so reliable.
altitude valve
We use a combination of different admixtures vault.
that are metered into the mix, and depending on
specifications, the mix may also include two types of Xypex additives
which enhance the watertight properties and corrosion resistance of
the product.”
Lasko said the focus on quality ensures customers know they can
install products with no concerns, an approach that has solidified
their relationships. One recent endeavor helped further deepen those
relationships. The company participated in NPCA’s inaugural Precast
Days event in October 2019, and the return on investment played out
right before their eyes. Lasko said they hosted engineers, contractors
and individuals from municipalities.
“The one common response was, ‘Wow, we didn’t know what it
took to make the product’,” he said. “For the guys who see the end
product, to hear them say that is wonderful. Engineers learned more
about the precast industry, and we are working one-on-one with
them on certain products, so it really ties all of us together working
as one.”
“What I saw here as the owner of the company also was the
enthusiasm among the employees, who were excited about doing
something like this,” Paul Jr. added.
THE RIGHT WAY
Carrying the growth mindset and employee focus into the future,
Paul Jr. sees a lot of good yet to come for the company his father built
seven decades ago. He has always been cautious to grow in logical
precast.org 27“We have the formula. If the wheel isn’t broken,
don’t fix it. Make it better.”
– Eric Lasko, Monarch Precast; NPCA Master Precaster & Leadership
NPCA Graduate
ways. Rather than adding a product line just to add it, he focuses on
enhancing current lines, which will continue to be the case. Lasko
appreciates this focus.
“We have the formula,” he said. “If the wheel isn’t broken, don’t
fix it. Make it better.”
For Paul Jr., the success is sweeter because the employees he
cares so much for are succeeding right alongside the company.
“Our team of dedicated employees realizes the emphasis we put
on quality, and they understand the value of customer service,” he
said. “That’s what makes us unique and has given us the success
that we have. I enjoy helping them see their potential; to give them
the realization that they have a future with the company and a
vested interest in the company.” PI
Kirk Stelsel, CAE, is NPCA’s vice president of communication & public affairs.
28 PRECAST INC.A DV E R T I S E M E N T
precast.org 29GREEN PIECE
The Seven Wastes
Waste #4:
Waiting Waste
By Shari Held
Editor’s Note: This is the fourth article in a year-long series about how seven common types of waste
in manufacturing can create unprofitable activity and how to address them in your plant.
I
t’s a sight precast plant owners and managers dread – seeing workers waiting around. The reasons for
wasted time are many: workers don’t have what they need, employees need clarification on a process
before being able to proceed or a machine is either down or in such high demand that team members
must take turns. Whatever the cause, waiting creates a bottleneck in the process and it’s costing you
time and money.
WAITING WASTE IN PRACTICE
When Henry Ford put the assembly line concept into action, he was addressing one of the seven wastes
lean manufacturing works to reduce or eliminate. When there is a steady flow down the line, nobody is
NPCA file photo
waiting around and any inaction is obvious because it impacts those before and after you in a domino-like
effect.
Wade Pink, president of Pink Precast in Dorchester,
Ontario, identified three things that contribute to the
majority of waiting time for his company: waiting
for the overhead crane to become available, waiting
for the mixer and waiting for the concrete bucket to
return to the production area to pour the next forms.
Earlier this year, the company expanded its plant,
making it three times its original size. Today, it’s one
long building with the mixer located in the front third
of the facility. This creates a long distance between
the mixer and crew at the other end of the plant.
Optimizing the plant layout for efficiency is essential
for decreasing waiting waste.
“We knew when we expanded that we’d have a bit
of a challenge because of the distance we were ending
When working on high-volume products, it’s important employees
have an efficient system from prepping a form to placing product
NPCA file photo
into the yard or onto a waiting truck.
30 PRECAST INC.up from our mixer,” Pink said. “We’re now in that exploratory “When materials are promised and they don’t come, we have An organized
plant can
phase, trying to figure out solutions we can implement to help to reschedule or go back to the drawing board, maybe even take
help eliminate
get the concrete down the plant. When everyone is standing something out of production for the day,” she said. waiting
around waiting, it can really erode employee morale.” Kitchner said another hang-up can occur during quality waste.
Megan Kitchner, owner of Atlantic TNG in Sarasota, Fla., control checks. If a detail is missing, production stops until the
has noticed an increase in waiting for materials from suppliers plant receives the necessary information. But wasted time by no
during the COVID-19 pandemic. means is limited to the production floor. It is a daily occurrence
precast.org 31You can also read
