Smart-Up^® UHPC Helps Contractor Beat the Clock in Cedartown, GA

Site Setup and Logistics

Smart-Up helped plan logistics from the outset. “It’s really important to plan ahead when you're dealing with UHPC,” says Hannah Tzabari, Lead Product Engineer at Smart-Up. “You want to minimize how far the buggies travel, place the mixer high enough to pour downhill, and make sure everything moves smoothly from batching to placement.”

The team staged the high-shear mixer on the high side of the bridge and arranged boxes of steel fibers, admixture drums and premix supersacks within easy reach of the crane.

Formwork Preparation and Sealing

Smart-Up best practices emphasize that tight, watertight formwork is essential to successful UHPC placement. Forms must resist hydrostatic pressure and prevent leaks.

“We always remind contractors the material will find any weakness, so it's critical to spend time getting the forms right,” says Robert Taylor, PE, MBA, Business Development / US Sales, Smart-Up UHPC. “If the forms aren’t sealed properly, you're going to lose product and time.”

Taylor says crews with Williams Contracting worked nearly a week to ensure the forms were properly sealed. “That was worth every bit of effort they put in. We didn't observe any leaks underneath.”

Fulmer adds that Contech, supplier of the bridge’s precast panels, also played a key role. “Contech had experience forming these beams,” he says. “They suggested we use inserts so we could pull everything tight from underneath. That was crucial.”

UHPC Batching and Quality Control

Rain delayed the start until 10:00 AM. Once underway, UHPC was batched in a high-shear mixer using Smart-Up’s proprietary premix, fibers, and admixtures.

Crews followed detailed batching protocols to maintain consistency and performance. The dry materials were loaded first, followed by water, then admixtures. Fibers were added last to ensure even distribution. The three team members involved in this stage wore full protective equipment per Smart-Up’s safety protocols—including respirators, gloves, and protective coveralls.

“The mix includes fine powders and reactive agents,” notes Tzabari. “Proper PPE is not optional. We make sure everyone is protected during loading and cleanup.”

Each ingredient was carefully measured to match Smart-Up's approved mix design.

“We follow a precise sequence,” says Tzabari. “Premix goes in first, then we add water and admixtures. Fibers go in last to make sure they disperse properly—and we time the mix to hit a specific flow range.”

Flow was tested using a seven-inch spread test. If a batch came out too tight or too loose, small adjustments to water or mixing time were made on the spot to bring it into spec.

Mockup and Placement Execution

Before the actual bridge placement began, the team conducted a mockup pour, required by Georgia DOT for contractors new to UHPC. “Sometimes the DOT wants a practice run,” says Tzabari. “We poured the first buggy into the mockup to get inspector approval—and then went straight to the bridge.”

With approval secured, the crew then moved immediately to full bridge placement. Material was transported uphill by buggy and poured into the joint using a custom-built wooden head bucket — designed on site to guide and shape the flow of UHPC.

“I thought that was impressive,” says Taylor. “They built a lightweight form that could ride along the edges of the joint and shape the UHPC as it flowed in. It was a simple solution, but it gave them a lot of control and produced a clean, uniform surface.”

Fulmer was struck by how easily the material moved into place compared to conventional deck mixes. “The UHPC definitely flows,” says Fulmer. “So instead of using your standard Class D mix on deck or whatever, it just literally flows through the cracks to tie everything together with the rebar already prefab into the beams.”

Despite the late start, the team found its rhythm quickly. Batching, transport, and placement all proceeded smoothly throughout the day.

“Even though we got delayed in the morning, we wrapped up by 2 p.m.,” says Tzabari. “That was a really efficient mixing day.”

Cleanup and Post-Pour Procedures

Cleanup began immediately. “There’s a tight window once the last pour goes down,” says Taylor. “If we wait too long, you’re chiseling out hardened concrete.”

“If you let the material set up, it’s almost impossible to get off,” adds Tzabari. “So we always clean right away. They flood the mixer, wash down the buggies, and scrape the deck,” she says. “It’s about staying ahead of the material.”

“Nobody stood around,” Taylor adds. “All of the team grabbed shovels and scraped the deck. Good crew.”

Final Outcome and Reflections

The bridge reopened April 14, 2025—exactly 90 days after the road was closed. From the moment the project began, the team worked against the clock. Between a rain-delayed start, a tight formwork schedule, and an unfamiliar material for many crew members, there was little room for error.

But the collaboration between Williams Contracting, Smart-Up UHPC, and Contech delivered.

“At first we didn’t know exactly what to expect,” Fulmer says, “but the Smart-Up team provided videos and conferences that gave us a better idea of what was going to happen. The UHPC is a little different, but overall, it seems like a great product. “If it comes up in specs again? Yes, absolutely. I’d use UHPC,” he adds.”