Length Of Time To Install A Truck Scale?

A common question we often get is how long will a new truck scale take to install. Just like many other components of a truck scale project, it really depends. In general a new steel deck truck scale with foundation will take around 7 days, while a new concrete deck truck scale and foundation will take closer to 3 weeks. However, if you are replacing an existing truck scale and reusing the foundation, a new truck scale can be installed in 1 day.

So what drives the length of a truck scale installation projects?

1. Deck Type:

   Steel deck truck scales can be installed in one day or less by an experienced scale installation company. This is because unlike a concrete deck the steel deck scale is ready to use as soon as it is calibrated. A concrete deck scale; however, will require at least 2 weeks after the scale deck has the concrete poured on-site to cure. If you don’t let the concrete deck cure all the way it will risk cracking and cause major structural issues for years to come. Bottom-line concrete deck truck scales take longer to install then steel deck truck scales. Learn More About Truck Scale Deck Types.

2. Foundation Type:

   The type of foundation will also determine the length of the project. Standard above ground foundations can be formed and poured in 2-3 days. They will also require some cure time. A pit foundation requires significantly more work; this means it will take closer to 4-5 days to form and pour. There are ways to shorten these time lines. In projects where it is crucial to minimize downtime we can often pour a high-early concrete mix. This mix will cure much faster than the standard mix although it does cost more because of the concrete additives that have to be used. Bottom-line, pit style foundations take longer to install then above-ground truck scale foundations. Learn More About Truck Scale Foundation Types.

3. Other Site Considerations

   The final item that determines the length of a truck scale installation project is whether all the secondary connections are ready and in place. By this we mean have you had electrical power run to the scale location, is the conduit run from the scale to the scale-house, is the PLC/HMI setup and ready to accept the new scale data, etc. Bottom-line these are all the ankle-biters at the end of project that tend to take much longer than anticipated. The key here is to have a clear game plan of who is responsible for what; meaning what is the scale company responsible for and what are you responsible for. Bottom-line, plan ahead and these tasks wont extend your project timeline, don’t plan ahead and they may become the longest portion of your truck scale installation project.

What Are The Different Scale Reports?

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3 Main Types of Scale Reports

All Legal for Trade weighing applications must meet the standards of their governing body to buy and sell product by weight. The various governing bodies require documentation of scale calibrations to ensure the scales are within acceptable tolerance. In this article, we will identify and discuss three of the most important scale calibration documents required by state Department of Agriculture and Consumer Services, Division of Weights and Measures, and Packers and Stockyards. The following reports must be completed by a licensed scale technician and submitted when appropriate to the governing agency. All parties are required to keep a copy of the reports.

1) Certificate of Calibration

The most common documentation of scale calibration is seen on the Certificate of Calibration. This report gives various types of information that are used to identify the scale. On American Scale’s Certificate of Calibration, there is a top block for filling in information that will identify the scale make, model, and serial number. There are also identifiers for scale identification, location, and environment. As you move down the report you will have a section to identify the test weights that were used in the calibration. Test weights must be checked every year by a Standards Lab. The report lists the set identification number, date last calibrated, and the N.I.S.T. number. Finally, the report shows detailed information to be entered by the technician based on his findings. A corner test is performed ensuring accurate weighments throughout the scale. An overall build-up test is performed to find linearity, tolerance, and potential calibration errors. A Certificate of Calibration is a great document to keep on file to track calibrations and reference during audits.

2) Truck Scale Report

The truck scale report is a large document that can be used to easily track a scale’s performance. A truck scale report will give pertinent information for identifying the scale and the type of device being used to for weight read-out. This report is an especially useful tool in determining corrective actions for a truck scale. A section on the report is dedicated to the various key parts of a truck scale to include approaches, platform, rock guard, platform clearance, foundation, suspension and grease, checking, and load cell condition and size. All this information is needed to help the service company better understand why recurring issues may be happening. The final sections of the report show the findings of the scale when under a load. A certified weight amount is placed on the scale in increasing increments. These increments are recorded to show build-up errors. Next, the report will show weighments over each load cell and section of the scale. These findings are recorded before adjustments are made. As the scale is adjusted and calibrated to standard, the report will reflect the weighing condition which the technicians left the truck scale. Using a Truck Scale Report is a great indicator of possible issues occurring with the scale as it will reflect areas of the scale that have continual errors and what has been done to correct these errors.

3) Livestock Reports

Monorail Scale Report

One type of livestock report is the monorail report. A monorail is a single, overhead rail used in most processing plants to push carcasses or products through the production rooms. Monorails that weigh carcasses which will be bought or sold by weight are required to be checked, calibrated, and documented for by the Packers & Stockyards Division of the Federal Trade Commission. Monorail reports are very tedious reports, but they provide a great deal of information that can protect a buyer or seller should a weighment ever be questioned.

Livestock Scale Report

The most common livestock report is the livestock scale report. The livestock scale report is like a monorail report. The report must be filled out by a licensed technician and submitted to Packers & Stockyards. A livestock scale is any scale used to weigh live animals. Livestock reports are required by the Packers & Stockyards Division. Livestock scales can be for multi-animals or single animals. It is important to remember that not all livestock weighing applications are legal for trade. Consult with a technician before purchasing a livestock scale as it may not meet NTEP standards, and a legal Livestock Scale Report cannot be filled out for that scale.

Closing Words

At American Scale we strive to bring you informed and useful content on all things scale related. Be sure to check out our legal for trade truck scale system articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. We also have articles on scale accessories, common problems to prolong your scales lifespan, weighing applications as well as what scale indicator works best with your junction box. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' and “How Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership.

3 Reasons You Should Consider Replacing Your Truck Scale

Truck Scale Issues To watch For:

1. Indicator Obsolete:

   Scale indicators are the real brains of any scale system. Overtime scale indicators will become obsolete. This leads to the parts for them not being available any longer. This becomes a particular problem with digital scale systems. Since digital scale systems use proprietary digital signals to transmit data from the load cells to the indicator you can’t just connect any analog indicator. In particular Mettler Toledo scales face this issue as many of their early digital indicators are now obsolete and require replacement.

2. Structural Scale Deck Issues:

   The most obvious reason that you may notice yourself when looking at your scale is the deck or weighbridge is falling apart. This can be cracking in the deck whether steel or concrete. It can also be less noticeable issues such as the deck itself flexing under load, this causes the scale not to repeat or return to zero. Other signs are serious rust or scabbing on the structural I-beams of the scale. Structural deck issues are by far the most serious safety issue; by not addressing it you are risking a truck and its driver falling through the deck.

3. Scale Foundation Issues:

   Key to a quality scale system is a strong scale foundation. Whether above-ground or pit style, scale foundations can deteriorate overtime. A major issue we see is foundation piers sinking. Given the piers support the load cells and therefore the full scale dead load sinking is not uncommon. As the piers sink the scale will no longer be level and will cause serious weighing errors.

4 Reasons to Sign-up for a Scale Calibration Program

Scale Preventative Maintenance Service Agreement

A Preventative Maintenance Service Agreement is a great way to ensure accurate weighments as well as track potential problems occurring with your weighing applications. During a Preventative Maintenance trip, technicians will check the internal and external features of your scale to ensure proper functionality while also checking and adjusting calibration. Many scale issues can be found during a Preventative Maintenance check that could reduce scale down-time and decrease weighing accuracy. The following are 4 reasons why you should sign-up for a scale calibration program:

1.  Mechanical Integrity

While performing a Preventative Maintenance check on your scale, technicians will inspection key mechanical features of your scale that could be failing. Mechanical parts such are pivots and bearings, load cell cups, links, and load cell stands are all common areas that a scale will wear due to use, age, and environment. It is important to have these parts inspected routinely to ensure your scale has great repeatability – ability to repetitively weigh accurately – and that the scale is not facing other major issues. Seldom, the wearing of these parts are indicators of a major underlying issue.

2.  Electronic Calibrations

Most scale these days features electronic indicators or scale heads as well as electronic load cells. These electronic parts are tested and evaluated during a Preventative Maintenance check to ensure accurate performance. Load cell values and indicator calibration are written down to compare against recommended values as a gauge for potential failure or accurate performance.

3.  Accurate Weighing

Scales often act as a cash register for many operations. Products are bought and sold by weight, or weight is tracked to reflect production. During a Preventative Maintenance check, technicians are guided by the scale standards set forth by Handbook 44. By using the standards of Handbook 44, technicians know how much weight should be used to test your scale and what the tolerance levels are to ensure accurate weighing. Through time and use, a scale will drift away from proper calibration. A Preventative Maintenance check will ensure that your scale is routinely brought back to its correct calibration to save you time and money.

4.  Legal Standards

Scale applications fall under different agencies and protocols governing their required checks and documentations. Most states require annual checks and calibrations while the USDA and others may require quarterly or monthly. By having a Preventative Service Agreement, you can assure that your company stays in compliance with appropriate scale checks and documentation.

Want to learn more about our calibrations programs; checkout out more details here.

Steel Deck or Concrete Deck Truck Scales: Which Is Best For Me?

Steel Deck or Concrete Deck Truck Scales

What’s the difference between a steel deck and concrete deck truck scale and which one is best for my application?  

Steel Deck Truck Scale
Steel Deck Truck Scales are built with all heavy duty structural steel.  This will include steel I-beams running the length of each scale module.  Each manufacturer has slightly different designs for their I-beams ranging from the size, number, and shape.  Each manufacturer will claim their design is superior.  In our experience they all perform about the same assuming you are buying from a top-tier scale supplier (B-Tek, Mettler Toledo, Emery Winslow, Rice Lake, Cardinal, Fairbanks). A steel deck typically involves less initial cost – there is no investment in concrete or the labor to pour it. A steel deck scale weighs less, which makes it easier to move or relocate if needed. It can be fully operational within a day at your site, reducing production downtime and operational impacts.

Pros: 

• Faster installation as no concrete cure time is required

• Easier maintenance as the deck modules can be lifted 

• Reduced installation cost as fewer trips to complete job are required by scale dealer

• Higher resale value

• More custom profiles and sizes available (particularly extra low-profile)

Cons:

• Scale surface can be slick when wet

• Higher shipping cost since they are heavier 

Concrete Deck Truck Scale
A concrete deck truck scale is very similar to a steel deck truck scale, but each scale module has an open top for concrete to be poured into each deck, bonding the support beams of each module. A concrete deck needs approximately 21 to 28 days to cure, it offers greater resistance to rust and corrosion from road salt and generally requires less maintenance than steel decks, helping to extend the life of the scale. A concrete surface also provides better traction with rain and snow. Because of their design, concrete decks distribute the load over a wider area than steel decks.  Concrete deck scales were more common 10-15 years ago; however, they are still installed today.  

Pros: 

• Better traction in wet or slippery environments

• Reduced risk of rust or corrosion given there is less metal in the scale

• More mass which means there is less friction and stress on internal parts

• Hold up to acidic and chemical type environments well

Cons:

• Longer installation time as it takes 3-4 weeks for the scale deck concrete to cure to the proper PSI strength

• More difficult to move at a future date if you need to relocate the scale as each panel weighs ~25,000lbs vs ~8,000lbs for a steel deck

• More difficult maintenance due to the weight of the scale which can lead to higher maintenance costs

Conclusion

Choosing between a steel deck or concrete deck will come down to preference. Understanding your work site will help you figure out which scale deck will work for you. Our Learning Hub is a great place to start. For more detailed articles, check out “Truck Scale Foundation Types” or “How Muc A Truck Scale Cost?”. The learning hub is a great resource filled with articles that can help eductae you during your truck scale journey.

Truck Scale Foundation Types: What Are The Differences?

Truck Scale Foundation Types

The foundation will determine the lifespan of the scale and the lifespan of the scale will determine how much money stays in your pocket. The truck scale foundation is the lowest load bearing part of the scale. Even the smallest imperfections in the foundation can cause weighing errors and unintended wear and tear on the scale. The slope of the site and soil conditions must be examined carefully before construction, otherwise it could lead to problems down the road. There are three types of truck scale foundations: the pier foundation, the beam slab foundation, and the pit style foundation. 

Pier foundation
The pier foundation has “piers” that support each load bearing point. Typically some of the foundation is put below frost line so that when the ground freezes and thaws it doesn’t have any negative effects on the scale or the foundation. Pier foundations are commonly found in the north where the ground freezes more often. 

Beam slab (floating slab) foundation
The beam slab foundation has concrete beams that run the entire length and width of the scale. Typically the beam slab foundations are stronger than the pier foundation but are more susceptible to the cold.

Pit style foundation
Lastly, the pit style foundation has pits of varying depths underneath the scale. Each foundation will have different sized pits based on the scale and topography, but there is a minimum depth to allow technicians to access components under the weighbridge. Pits can require extra cleaning because debris can gather in the pits over time. 

Truck Scale Foundations: Pit vs. Above Ground

Truck Scale Foundation Types

How Technology Is Changing Truck Scales

The Future Of The Scale Industry.

Technology is changing every aspect of our lives. Advances in what once seemed transformational are now fundamentally changing the way we collect and use data. We have already gone from analog to electronic load cells, scale calibration has become a lot simpler due to systems able to monitor any changes in load cells. We even have remote displays and scoreboards for added convenience. Scale manufacturers are working to adapt new technology to the already evolving industry. Long are the days of just wondering if you want a stainless steel setup, or a steel deck over a washdown one. The changes have already started. The benefits of having digital integration within your scale operations are having a huge impact on profitability because of the information available from data collection. Technology is now the catalyst and data is the output.

What is done with that data will help your business to truly evolve.

A view of the entire system

While most industries have evolved with technology, the truck scale industry has not evolved as rapidly. Troubleshooting a scale can be difficult because problems can occur in various places. It can take hours to find a problem the traditional way using a voltage meter to check many locations on a scale.

Fortunately, new technology empowers service companies to see what’s happening with the entire system. You can now predict issues in advance of failure and get notifications if a problem occurs.

These technological advances enable service companies to identify, diagnose and solve any problem found on the scale saving time and money.

Accuracy streamlines processes

Digital integration automates processes, captures available data, and provides a digital ecosystem for storage and troubleshooting. This technology sends notifications to the service company, informs them of the issue prior to arrival, and decreases downtime for the scale.

Understanding the problems and potential threats help you to strategically approach the situation. For example, if a scale is not weighing correctly, it could impact your invoices and inventory. The scales that are available today can measure up to 100,000 pounds in 10-pound increments versus 20-pound increments, thereby being twice as precise.

It’s also important to understand how to take care of a scale to proactively prevent problems from occurring. The technology that’s available includes precautionary measures, helping you to protect your scale from threats such as lightning. A quality scale will guarantee this type of protection.

The service provider partnership

While these technological advancements help scale owners narrow down the problem, it’s still recommended to utilize service providers. We will help you keep up with new developments and stay on top of regulatory standards. It’s easy to keep us in the loop, too, because diagnosing and notifications are automated.

Without real-time data and collaborative relationships, it can sometimes hinder successful management. Having a strong partnership will help you make sure you know about changes, especially because technology is always evolving. Therefore, it’s important that you see your service provider as a proactive problem solver, empowered by data and notifications to correct any issues before the scale goes down.

Profitability comes from the ability to adapt to data being provided from having up-to-date technology. Data analytics is a powerful tool that has the potential to enhance efficiency and improve your service. Good data helps you sift through all the noise and quickly understand the issues and opportunities. Leveraging data will be the future game-changer for the scale industry, and it will be expected by your customers. American Scale Company will help you stay ahead of the curve!

Checkout more here

At American Scale we strive to bring you informed and useful content on all things scale related. Be sure to check out our legal for trade truck scale system articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. We also have articles on scale accessories, common problems to prolong your scales lifespan, weighing applications as well as what scale indicator works best with your junction box. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' and “How Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership.