At Techo-Bloc, we believe care and consistency are key when it comes to maintaining the exceptional quality of our products. From start to finish, our manufacturing process is meticulously crafted to ensure excellence.
Achieving such high standards didn’t happen by accident. It took many years of methodical testing, research and innovation. Today, our factories are world-class operations that we’re proud to call our own.
Here is an inside look at our methodology and a step-by-step tour of our pavers’ production process that spans from the moment raw materials enter our site until we package the final product for shipment.
Gathering Materials
Our manufacturing process begins with the raw materials which are composed of our proprietary blend of aggregates and sand – Each raw material being subjected to a strict sieve analysis. These materials are then transferred below ground onto a bucket conveyor specifically built to maintain their respective gradation, and therefore ensure consistent quality of our specially-chosen mix.
That bucket conveyor then feeds the aggregate and sand up into our silos. The use of silos is strategic because they help keep the consistent gradation of the raw materials as opposed to standard bins.
Pigment Dispensing
Just around the corner is our pigment dispensing system where we air blow granular iron oxide pigments into the mixers. This dispensing system is tightly controlled to 1/16th of an ounce to maintain consistency throughout so you don’t have to worry about contrasting or uneven color affecting your design.
Concrete Mixing
With the mix of aggregates and pigments loaded in the planetary mixers, cement, water and specialized admixtures are added with meticulous care. Sensitive microwave probes monitor the moisture content of the concrete mix. Even the slightest inconsistency in the water:cement ratio from batch to batch can result in variations in color and strength.
After the water is added, the concrete mixture is divided and transferred into three separate hoppers, each containing a specific color that provides multiple blending options for any design. After this step, each blend is transferred onto three separate conveyors taking them further down the path that will eventually produce the blocks you know us for.
The conveyors carry the color blends from the mixer to the production machines. There, the mixture is poured into the various molds that create the wide range of products we offer.
The concrete mix is vibrated in the mold to consolidate it and then is compressed under immense pressure (over 60,000 psi) to make it as dense as possible. From there, the mold is lifted and the freshly-pressed blocks are ready to head off to the curing chambers.
Curing and Quality Control
We value innovation, service and quality above all else here at Techo-Bloc. That is why we painstakingly check every single product that comes off of our production line.
Right when the blocks come out of the machine, we use laser technology to measure the thickness of the individual units. As a failsafe, we also apply precision-machined height gauges that make sure that our tolerances are well within our rigorous standards. Any blocks that don’t pass the evaluation are immediately removed from the production line. We will not sell a single block that is not up to our — and our clients’ — exacting expectations.
All the blocks that do pass are moved to an elevator. Two layers of product at a time are brought up to where the fully automated finger cart picks them up and moves them inside one of our curing chambers.
For some companies, the curing process of these blocks would take up to 28 days to acquire enough resistance. But with our specially designed curing facility, we obtain the same level of resistance in as little as 9 hours, so we can get our product to you as efficiently as possible, keeping your project moving on schedule.
Once our product is fully cured, the automated finger cart once again picks the blocks up and brings them over to what we call a “lowerator”. The product is lowered two layers at a time and goes through another quality assurance check station. Precision-machined height gauges are used once again to confirm the quality of each individual piece that comes through the production line. Color, texture and overall appearance are also scrutinized before the product can advance to packaging.
And once again, any piece that does not meet our high standards will not be passed on to the customer. We are committed to only selling quality products, so you never have to worry about poor quality pavers slowing down your project or damaging your reputation.
You also never need to worry about the resistance or durability of any of our products. Since our products are manufactured to Canadian specifications, they are built to withstand any harsh climate, resist de-icing salts, and are backed by an industry-leading warranty. We believe that we succeed by helping you succeed.
Packaging
After the sand, aggregates and pigments have been mixed, molded and cured in our factories, it’s time to get them packaged and prepared to be sent to you.
From the quality assurance line, a cuber grabs the product and transfers them to a wood pallet for shipping. The pallet is built layer by layer until it is full and ready to be moved to the packaging line.
At the packaging line, our team carefully installs a gusset bag and a top sheet that protects the product from any weather during shipping. A machine then shrink wraps the entire pallet as one final layer of protection, and it is sent out to the yard, ready to be shipped out for your next project.
Ready to Get Started?
Every single paver that leaves our factory has been created with careful precision, dedication to quality and an overwhelming passion for maintaining a product our valued customers recognize and appreciate apart from our competitors.
At Techo-Bloc, we have a passionate commercial team excited to work with you on your next unique design. This team can assist with special sizing, custom colors and non-standard patterns (like we did for the Woods Hole project), and can offer engineering expertise to help you succeed on any project you bring to us.
Contact us today to discuss how our expert team and cutting-edge pavers can make your next commercial landscaping project truly spectacular.
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