Most people might think that talking about concrete isn't very interesting. Let us convince you otherwise (not that you're just anyone; maybe you're really into concrete, but we'll NE-VER know!). Back to our concrete! (uh, sheep)
The story of a concrete product begins with a little magic - YES, a mix of passion and effervescent madness typical of Patio Drummond - and a specific need.
Chapter 1: Ideation
We start by imagining the product and try to describe it as best we can to our designers. The first spark that drives us to conceive a new product can come from a market need or a specific request from a client. Once the initial discussion is complete, we begin the process of drawing and 3D planning the product.
Chapter 2: Design
As soon as the plans are received, we begin designing the mold in which the product will be cast. Molds can be made from various materials used together or individually, such as high-performance plastic, rubber, wood, or metal. Several parameters help us determine the material to use: the size of the finished products, the total quantity to manufacture, the machine or department that will cast the part, and the complexity of the parts. One of the most important steps in mold design is planning the demolding process. We have to think of everything: negative angles, part edges, size for handling, how the reinforcement fits into the part, if applicable, the finish, etc.! This is where we might scratch our heads a bit or stroke our beards thoughtfully. The mold requires ALL our attention. There's no room for error when producing multiple products with the same mold! Once the mold is made, the testing phase begins: it's greased, and its conformity is validated. This means we cast several parts and put them through all sorts of trials. Like Père Fouras in Fort Boyard, we can be quite cunning and meticulous. If the mold doesn't allow us to create a product that meets our expectations, we start over until we have the more-than-perfect product. Depending on what we need to produce, we might call on an engineer to ensure, for example, that the manufactured concrete parts are compliant, safe, and won't fall on anyone's head - it's never happened, but we'd rather not take any chances!
Chapter 3: Production
Our favorite chapter! This is when we start to see the fruit of our labor. We organize the work to be as efficient, ergonomic, and fast as possible. Depending on the parts produced, we clean and grease the mold. We then place the reinforcement if reinforcement is planned for the item. An inspection might also take place at this stage depending on the nature of the part and the project (we don't systematically inspect every product, because if we take our 18x18 Paving Slab, at over 10,000 slabs per day, we wouldn't be very efficient!) - However, we do inspect balconies that are installed on multi-story buildings, and we do so several times during the production process. The concrete placement follows and will require more or less finishing and vibration depending on the type of concrete used for the product (we don't vibrate our products for fun; it helps to even everything out and release air bubbles). Here, we work with three types of concrete. We're quite proud of that: it's unique to have 3 concrete expertises on a single production floor! Depending on the type of concrete, the placement is highly variable; dry concrete is worked a bit like dough used to make cookies with a cookie cutter, while hydraulic concrete (more "wet") is poured into a mold, much like a birthday cake! After the concrete is placed, we leave it alone to allow it to cure - this can happen in different environments depending on the nature of the product. The curing time (concrete drying) can vary from product to product, but we generally estimate one day. Fun fact, during curing, concrete releases a lot of heat and humidity due to the energy emitted by the chemical reaction involved in the concrete powder mixture (the concrete releases all the energy that was necessary for the powder to make it! Long live magic! Or... chemistry!)
Chapter 4: Finishing
Over time, we have become experts in manufacturing concrete products. It's true, Patio Drummond is like the Merlin of manufacturers - crazy, but with immense knowledge! Sometimes, a magician is required to make minor touch-ups or repairs to ensure we deliver a turnkey product to our clients! Finishing also means: special requests. It's at this stage that we consider our clients' needs and requests, such as sandblasting or applying a high-performance sealant. We can also polish certain parts or install reflective strips to provide additional visibility. As they say: "The sky is the limit."
Chapter 5: Packaging and Identification
We try to use as little packaging as possible. Packaging a 16' x 12' balcony would require A LOT of wrapping paper. Our slabs are stacked on reusable wooden pallets and then wrapped in plastic film for safe transport. All our products have identification that resists outdoor storage, allowing for quick loading and delivery of orders! Storage and handling after production are analyzed and efficiently managed by our specialist handlers. We move impressive quantities of stock every day: small and large products, the whole gang is involved! We are fortunate to have several impressive machines (lifts, overhead cranes, etc.) for all types of projects - and let's not forget, a little magic!
Chapter 6: Transport
Transporting concrete products isn't always easy, but every day we make deliveries all over Quebec, and several carriers pass through our administrative center to pick up various products. We sometimes face challenges related to the dimensions of the pieces to be delivered. That's when we call on road escorts, flashing lights, and other measures. To comply with certain safety rules on construction sites, our clients have cranes and machines for unloading and installing our pieces. Chapter 7: Retailers Our clientele is very diverse; although many of our products end up in hardware stores to be distributed to consumers where they lived happily ever after (Maybe not until the end of time, but concrete is very, very durable, so for a very long time!), we also deliver to construction sites, municipalities, or even agricultural sites! End! So, that was the (brief) story of a concrete product at Patio Drummond!
