Construction mobilization enables contractors to begin a project right. Equipment, trailers, and the laydown yard are set up for the job ahead before the inevitable chaos begins.

Proper construction mobilization requires foresight. Concrete costs quoted by estimators can be wishful thinking for some Ultra High-Performance Concrete (UHPC) projects, especially if the UHPC doesn’t work with traditional concrete project execution. 

What if you need to split the job and remobilize? What if space and traffic constraints require a separate yard off the job site? What if you need more labor or equipment than a traditional concrete project does? 

These possibilities warrant more scrutiny during bidding and contracting. The owner and general contractor relationship can quickly sour over an early scope dispute everyone should have planned for and that ultimately gets discovered in the field.

We see UHPC projects with hidden mobilization costs that aren’t necessary. Poor planning and vendors’ lack of diligence can increase project costs by as much as $1,200.00 per cubic yard (CY).

UHPC: Construction Means and Methods

Once you mobilize, you’re committed to following through on the contract scope. The unit cost of UHPC can escalate if your construction plan doesn’t align with reality. Below are a few key risks to consider when preparing your budget and mobilization plans.

• Labor – Personnel needs depend on the UHPC product and delivery approach. Hand-mixing admixtures, steel fibers, and ice in the yard adds days to the job and contributes to additional personnel costs. Ensure the full mixing operation is understood, and that you’re utilizing UHPC that doesn’t require extra labor.
• Equipment – Rental equipment may be needed, and may need to sit idle or return for different stages of the job. Understand what specialty equipment the UHPC vendor may require. Moving quickly from batch plant mixing to standard ready-mix deployment helps to reduce equipment mobilization and associated overhead.
• Increased Maintenance of Traffic (MOT) – Additional traffic control may increase costs. If hand-mixing drags on and batching can’t be centralized in a plant, it might require travel from the yard to the pour site and keep the traffic crew intermittently busy. This may incur extra expenses and permits.
• Other Logistics – materials delivery, specialty handling, and transportation costs can be minimized with effective and complete mobilization. Storage, security, water sourcing, and sample testing timelines warrant early coordination. Re-mobilization could be necessary and compound additional expenses. Establish a clear plan for each step in the UHPC process. 

UHPC: The Bid and Budget Phase

Mobilization has standard budget assumptions based on the scale, scope, and jurisdiction of the project. A Lump Sum cost might be used to approximate what is needed for crew setup and construction readiness. Benchmarks from previous concrete jobs are only valid if your UHPC can truly be installed with the same outfit.

A typical bid process involves an estimator using competitive unit costs without always considering nuance. The amount of detail in the request for proposal (RFP) and the contractor’s familiarity with UHPC may create gaps in understanding the actual field requirements. Keep in mind those means and methods and how important it is to plan ahead.

Vendor quotes and templated concrete costs only go so far. They may assume that a standard crew has adequate labor, equipment, and space onsite. Accurate costing requires a deeper understanding of how the UHPC will be mixed and what is needed to properly pour it. 

Too often, the budget is underestimated because the UHPC they selected can’t be installed like traditional ready-mix. Working with a partner such as Cor-Tuf that accommodates typical batch plant mixing and ready-mix deployment is essential to avoid complete mobilization cost oversights.

UHPC: Material Procurement

Establish what UHPC vendors are providing and how that may impact your projects. There may be multiple vendors that can meet specifications (or there may not), but ultimately you also need schedule and budget confidence.

Many UHPC vendors include mixing assumptions and QA/QC requirements. Indicative quotes may not be specific enough to understand their impact on the bottom line, so it’s important to understand whether your typical concrete crew needs to alter their usual procedures.

Receiving materials in small quantities, which requires additional storage, or using specialty equipment can add to mobilization needs—and costs. Performing traditional batching and ready-mix delivery will be key to achieving traditional concrete job execution. 

Address procurement complications with your vendor early and partner with someone who can get to a more accurate final unit cost. Understand whether you are receiving an all-in product that’s easily integrated into your construction plan or an alternative process that changes your mobilization.

Cor-Tuf UHPC: Avoid the Hidden Costs

All these undisclosed costs can add up to an extra $1,200.00/CY. Some vendors quote UHPC products that don’t work with typical concrete plans, and contractors don’t know until it’s too late.

This is why Cor-Tuf UHPC works the same way as traditional concrete, including batch plant mixing and ready-mix compatibility. We don’t experience the same budget blunders because we’ve done the work ourselves. We cut out the extra hand-mixing labor, avoid the requirement for a separate mixing yard, and price an all-in cost without special equipment and materials.

Don’t accept unnecessary risks on your next UHPC project. Work with a trustworthy UHPC partner, submit your bid, and mobilize confidently. Your sand, your cement, our Cor-Tuf UHPC.