Concast has sold products to every major electric and power utility in the country, and now is moving into the wind market.

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Originally focused on the residential market, Concast Inc. recently switched gears to serve the wind power industry. “We have focused most of our attention on the wind energy market since the housing market has taken a plunge,” General Manager Ben Olson says.    

The Zumbrota, Minn.-based company specializes in precast concrete products for the electrical and power industry. These include cable distribution trench systems for below-ground substation control, communications and power cables. It also produces box pads, flat pads, ground sleeves, splice boxes and vaults for the electrical and communication industry. It may be best known for manufacturing Fibercrete®, a high-strength concrete made of alkali-resistant glass fibers and steel reinforcing.   

The company is currently working on a waterproof box pad to be used at the base of the wind turbine under the three-phase transformer. It will prevent groundwater from entering the box pad, which causes corrosion to the transformer components. “There has been some groundwater issues around these wind farm turbines,” Olson explains. Concast is also working in the railway, wastewater treatment, cellular and industrial piping markets to make up for the residential slowdown.   

Concast just started to see some inquiries come in for the solar industry, as well. “We’re trying to keep our customer base as well as develop new customers in the wind power industry and other alternate energy sources that can use our products,” he says.   

The company plans to become more involved in these sectors in the near future. “We – just in the last three to five years – have made a dent into the wind industry, and we hope to capture more of that business and continue to grow with our current customers by coming up with new products to suit their ever-changing needs,” Olson says.    

Concast has sold products to every major electric and power utility in the country, Olson says. “The biggest difference between us and the standard precast concrete manufacturer is the production process,” he explains. The company applies the glass fiber reinforced concrete (GFRC) by a spray lay-up method, which involves spraying several coats of the material onto a steel mold. This results in a very thin sheet that, with correct reinforcing and rib placement, is comparable to a much heavier, thick concrete wall, he says.   

Its products – which can replace concrete and plastic materials – set the company apart. “We have competing products to both concrete and plastic, but a lot lighter weight than concrete and more durable than plastic,” he says. They are also resistant to fire, corrosion, temperature extremes and UV degradation from the sun.       

Concast follows a strong internal quality control program and practices. “We feel that we have a very high-quality product to begin with,” he says. “We screen all of them before they leave the facility. We have a 35-year warranty to stand behind them.”   

The company is also able to produce customized products. “We have the ability to work with our customers, and we do our best to meet any special needs that the customers have,” he adds.    

Concast prides itself on its turnaround time. “Most of the quotes are turned around the same day,” he says. “Calls are returned in an hour or two. We strive on giving our customers a fast turnaround and a quality product, and that has kept our business strong.”

Getting Hands Dirty
Concast’s manufacturing work force is “hard working,” Olson describes. “We have good-quality people who are not afraid to get their hands dirty. The majority of the crew has been with us for an average of 15 years and a good portion of them are upwards of 30 years.”   

Turnover is not a problem for the company, he adds. “Part of that has to do with how the company is able to with­stand the ups and downs,” Olson says. “And that is be­cause of the quality product we produce. Concast is constantly searching for improved production processes to keep our costs down and the quality of the product up.”