For five years, Dalmaray Concrete Products in Southern Wisconsin has trusted Helix Steel’s innovative concrete reinforcement product with simplifying its production processes, saving money and expediting its workflow. 

Dalmaray has been a leader in delivering precast water and wastewater products in Wisconsin and Illinois for more than 60 years, providing drywell and distribution boxes, concrete water well covers and more.

Superior Precast Concrete Reinforcement

“We’re known for our high-quality vessels that never fail,” says David Rasmussen, Technical Sales/QC, Dalmaray Concrete Products. As the person whose job is to ensure that precast production goes the right way and getting the jobs done right, Rasmussen and his team trusts in Helix Steel’s proven concrete reinforcement solution that provides superior strength and durability, while also delivering the right engineering for whatever job they are working on.

“The process is just much more efficient with Micro Rebar,” he says. “We used to have mesh that we would have to cut to the right size, then bend each section using a bender. Then we’d take the four straight pieces and tie each corner in. It took a lot of time.”

Precast Concrete Reinforcement Time Savings

Not having to assemble complex mesh pieces saves a significant amount of time. “When you factor in the human component, it saves us money. Our crew can do a lot more in the day. Before, a tank used to take us an hour and a half to put together. Now it’s only 45 minutes. We can do twice as many jobs in the same amount of time. Our whole production is more efficient.  We pour the exact amount on our belt with the sand, and pour it in with the mixer.”

Perhaps most importantly for Dalmaray is that Helix® Micro Rebar reinforcement simplifies the process and engineering accuracy needed to build precast vessels. Rasmussen adds that “Helix Steel has a hands-off product with the numbers to back it up.”

Once You Go with Helix Steel’s Concrete Reinforcement, You Won’t Turn Back

Although some of Dalmaray’s larger tanks and lids still use standard mesh, all of the other products have converted to Helix Steel’s reinforcement solution – and have no plans of turning back.

“Our crews love it. It’s safer than rebar. And even our customers are well aware of the benefits and appreciate how Dalmaray is focused on quality products.”

Asked what would happen if they were forced to go back to mesh, Rasmussen laughs and says, “I don’t know how happy the guys would be to go back.”

Precast just makes sense with Helix Steel. For more information on Helix® Micro Rebar reinforcement, a better way to build with concrete, contact Helix Steel today.

Rebar-reinforced precast structures have served the construction industry well, but a new reinforcement is here to make precast faster, cheaper and more durable than ever before.

Precast concrete products have been in use since the invention of concrete itself. Built in controlled environments, these vital components of our infrastructure are the backbone of healthy, efficient municipal systems. Failure is not an option.

That is why many precast companies are converting from unreliable rebar to Helix® Micro Rebar concrete reinforcement. From precast tanks to manholes, the precast applications are practically endless for Helix Steel’s concrete reinforcement that outmatches rebar and mesh.

So, what exactly is Helix® Micro Rebar concrete reinforcement? Instead of unmanageable lengths of rusty metal, it is a simple one-inch piece of steel, twisted and mixed with thousands of others into concrete before it is poured into the form, providing strength to practically every inch of the finished concrete structure.

Michigan-based Helix Steel created Helix® Micro Rebar concrete reinforcement almost 20 years ago, and since then has its product as a vital component in over 10,000 structures including mid-rise apartment buildings, warehouses, manufacturing facilities and even Seattle’s famous Ferris wheel. But precast companies have seen the greatest benefits.

Lowering Labor Costs for Precast Concrete Businesses

A large part of the precast process is the installation of concrete reinforcement. Having to find and retain experienced laborers, and settling with the time-consuming process of bending and connecting mesh/rebar by hand can be frustrating and expensive. 

Helix® Micro Rebar concrete reinforcement simplifies precast operations with fewer laborers – most precast water products require no rebar at all –  and dramatically cuts production costs.

“The process is just much more efficient with Micro Rebar,” says David Rasmussen, Technical Sales/QC, for precast business Dalmaray Concrete Products in Wisconsin. “We used to have mesh that we would have to cut to the right size, then bend each section using a bender. Then we’d take the four straight pieces and tie each corner in. It took a lot of time.”

An added bonus for choosing Helix® Micro Rebar is that it comes in convenient cardboard boxes, resulting in significantly fewer injuries.

Helix® Micro Rebar™ Concrete Reinforcement Cuts Production Costs

Precast companies spend significant money on buying rebar and mesh products, while also trying to stay competitively priced in an increasingly cutthroat industry. Helix® Micro Rebar reduces rebar installation time by up to 100%, reduces labor costs and expedites production.

“When you factor in the human component, it saves us money,” says David Rasmussen. “Our crew can do a lot more in the day. Before, a tank used to take us an hour and a half to put together. Now it’s only 45 minutes.”

Helix® Micro Rebar allows precast companies formerly limited in production output can now fit much more production into every work day.

Increasing Precast Strength and Durability

Producing precast vessels is one thing. Ensuring that they remain long-lasting for decades to come is something else. Focusing on the post-construction risk due to cracking is essential.

Helix® Micro Rebar concrete reinforcement is scientifically and real-world proven to be a stronger, more durable solution – with fewer complaints. The twisted steel acts like a screw, reducing concrete’s ability to pull apart and prevents cracks before they even start. In doing so, Helix® Micro Rebar maximizes the structural durability of precast structures against corrosion, earthquakes, water penetration and even explosions.

Helix® Micro Rebar reinforcement delivers precast structures with five times the tensile strength of rebar and withstands double the force needed to break concrete (1,600 to 2,000 PSI).

Superior Concrete Reinforcement with Engineering Support

One of the biggest struggles with fiber – a weaker rebar alternative – is that precast companies need to determine their own dosage rates. Engineering with every order is something that Helix Steel takes great pride in. Live assistance before, during and even after precast structure construction further eases the process of using a rebar alternative. Helix Steel has full code approval to carry building loads under the ACI 318, IBC and IRC.

NPCA Precast Certification Made Easier with Helix® Micro Rebar Concrete Reinforcement 

The gold standard in precast concrete plant certification is now easier to achieve with a reinforcement solution that creates a stronger, more durable product with plant operations that are safer, simpler and more efficient.

The Best Precast Concrete Reinforcement Alternative is Here

Who knew that such a small, twisted idea would prove to be a far better alternative to concrete reinforcement? Helix Steel did. And so did thousands of American precast businesses that trust its real-world results. For more information on Helix® Micro Rebar, a better way to build with concrete, contact Helix Steel today.