WaveLogix Concrete Sensors News & Updates

Boosting ROI in Bridge Projects: Insights from Dan McCoy

Written by Joseph Turek | February 16, 2025

If there’s one thing that makes a webinar stand out, it’s when the speaker delivers groundbreaking insights while smoking a cigar. That’s precisely what Dan McCoy did during our latest Wavelogix webinar, “Boosting ROI in Bridge Projects with Data-Driven Innovations.”

A third-generation bridge builder and civil engineer, McCoy shared his deep expertise in revolutionizing the concrete industry while enjoying a well-earned cigar—a moment that perfectly embodied his confident and seasoned approach to innovation. Interviewed by Joe Turek, President of Wavelogix, McCoy brought technical expertise and personal insight to the discussion.

A Legacy of Meaningful Infrastructure Work

Like his grandfather, McCoy believes that adding meaning to his work is just as important as technical excellence. He spoke passionately about engineers' responsibility in building structures that stand the test of time, ensuring safety and longevity for future generations. His experience working closely with the Federal Highway Administration (FHWA), which he calls the pinnacle of infrastructure research, has reinforced his drive to incorporate data-driven solutions into modern bridge projects.

Why Traditional Concrete Testing is Holding Us Back

In McCoy’s words, “If you’re still relying on cylinder breaks and periodic testing schedules, you’re already behind.” He detailed the significant disadvantages of traditional methods like AASHTO T 22, which relies on cylinder compression tests:

  • High variability, with up to 500% error margins
  • Long wait times delay crucial construction milestones
  • High labor and material costs
  • Inconsistent results due to environmental conditions

Instead, McCoy advocates for a shift toward real-time monitoring using Wavelogix’s REBEL® Concrete Strength Sensing System, eliminating the need for preset maturity curves and allowing construction teams to move forward confidently.

The Data-Driven Future of Bridge Construction

One of the biggest takeaways from the webinar was how AI, IoT, and smart sensors are reshaping the way we build. McCoy highlighted how REBEL® sensors provide:

  • Real-time strength monitoring up to 56 days and beyond
  • Calibration-free measurements, reducing setup errors
  • Lower variability than traditional methods
  • 50% cost savings compared to cylinder break tests

This shift isn’t just about efficiency but safety, sustainability, and maximizing ROI for infrastructure projects. McCoy clarified that using data-driven methods to assess concrete strength means projects can move forward faster—without compromising quality.

McCoy’s Vision for the Industry

As he leaned back, cigar in hand, McCoy painted a vision of the future: a construction industry where technology eliminates uncertainty, teams have access to real-time data, and project managers no longer have to deal with costly delays caused by outdated testing methods.

“We’ve got to stop thinking of concrete testing as a waiting game. The data is here, the technology is here—it’s time we start using it to build smarter.”

Q&A: Insights on Redi-Mix and McCoy’s First Bridge Project

During the webinar's Q&A session, McCoy was asked about his thoughts on Redi-Mix concrete and its role in modern construction. He emphasized that while Redi-Mix has been a staple in the industry for decades, its reliance on batch-specific quality control introduces variability. “What we’re seeing now is a shift toward real-time monitoring, ensuring that every mix, every pour, and every structural element meets the highest standards without waiting on lab tests,” he explained.

McCoy also shared a nostalgic moment reflecting on his first bridge project, which he was brought to as a baby. “I still drive by it sometimes, and it reminds me why I do this work—to build something that lasts.” His story resonated with attendees, highlighting engineers' personal connection and responsibility to their work.

Final Thoughts

McCoy’s insights, delivered with passion and a touch of old-school charm, impacted attendees. The combination of decades of hands-on experience and a forward-thinking approach makes his perspective invaluable to anyone in the industry.

For those looking to optimize their infrastructure projects and embrace the future of construction, the key takeaway is clear: real-time data is the new standard, and early adopters will reap the most significant rewards.

Want to learn more? Contact us at sales@wavelogix.tech to see how the REBEL® system can transform your next project.