Many manufacturers in our position might have turned to dry-cast production methods — faster, yes, but at the expense of surface integrity, structural performance, and long-term durability. That wasn’t an option for us. Instead, we leaned into our strengths: collaboration, innovation, and a commitment to engineering excellence.
Rethinking the Process, Not the Product
To meet our consistent 2-week lead time benchmark amid rising order volume, we initiated a full-scale production innovation workshop. Our entire operations and production team came together to develop a solution that preserved the integrity of our wet-cast process while scaling throughput.
The challenge? Enable same-shift double pours on five distinct product lines — without overextending labor, adding a third shift, or compromising our sustainability goals.
33 Tests. Zero Shortcuts. All Precision.
What followed was a rigorous phase of controlled testing and data-driven optimization. Over several weeks, our team ran 33 discrete tests involving:
- Alternative stripping PSI thresholds to accelerate mold turnaround without compromising edge integrity or corner strength
- Modified mixing speeds and durations to refine hydration and reduce air entrainment
- Adjustments to our proprietary mix chemistry, exploring accelerators and admixtures to optimize early-stage compressive strength
Initial trials weren’t promising. In one of our first PSI break tests, we registered just 77 PSI after 7 hours — below the threshold of our compression tester’s measurable range. Rather than scale back, we scaled deeper — into the science and mechanics of precast performance.
Achieving 24 hour Strength in Just 7 Hours
Through iterative refinement, we arrived at an enhanced proprietary mix design and a reengineered pouring and curing protocol. With this breakthrough, we can now reliably hit 2,675 PSI compressive strength within just 7 hours — a performance milestone typically reserved for 24 hour breaks.
This achievement enables us to double-pour five product SKUs within a single shift, effectively doubling output without extending hours or adding labor. We maintained our use of wet-cast forms, achieving the superior finish, edge sharpness, and durability our customers expect — while advancing lean manufacturing principles on the floor.
Quality, Throughput, and Sustainability: No Compromises
Importantly, this leap forward was accomplished without straining our team or our environmental values. We continue to utilize our closed-loop water reclamation system and maintain our commitment to resource-efficient production.
We didn’t pivot to faster, cheaper methods. We reinvented how premium wet-cast precast concrete can be produced at scale — proving that innovation, not compromise, is the path forward.
A Team of Problem-Solvers Behind Every Pour
This breakthrough would not have been possible without the dedication, technical insight, and tireless experimentation from our exceptional production team.
A special thank you goes out to:
- Brice Raynor, COO & Owner
- Cathi Giard, Director of Operations & Quality
- Lucas Burkhardt, Production Manager
- Vinny Cormier, Quality Supervisor
- Kevin Ranta, Production Shift Supervisor
- Will Landson-Trezza, Production
Each of these individuals played a critical role in brainstorming, testing, analyzing, and optimizing the process — a testament to the kind of teamwork and grit that defines EZ-CRETE. Their commitment to pushing past the obvious solution in pursuit of a better one has reshaped what’s possible in precast concrete production.
