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Testing Smarter: REBEL Sensors Evaluated by 17 State DOTs

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Concrete infrastructure projects demand high precision, reliability, and efficiency. To meet these needs, Wavelogix’s REBEL Sensors were deployed across 17 State Departments of Transportation (DOTs) from July 2023 to October 2024. With over 200 sensors placed in more than 60 projects, including highways, bridges, and road repairs, these trials validated the sensors’ ability to provide real-time concrete strength measurements.

This large-scale testing effort demonstrated how REBEL Sensors improve accuracy, reduce project timelines, and eliminate the need for traditional maturity curves. Below, we highlight key findings from different DOTs across the country.

Key Takeaways from Multi-State Testing

Comparable Strength Measurements

  • REBEL Sensors provided compressive strength readings that were within 16% of core samples at 28 days, a significant improvement over traditional cylinder tests.
  • Cylinder testing showed an average variability of 130 psi, while REBEL Sensors had only 63 psi variability.

Faster Decision-Making

  • Sensors enabled earlier traffic openings in multiple projects, reducing construction delays.
  • In TXDOT patching trials, sensors consistently reached target strength at least one hour earlier than cylinder breaks.

High Accuracy Across Mix Designs

  • The sensors effectively measured concrete strength in mixes with water-to-cement (w/c) ratios ranging from 0.32 to 0.55, covering a wide variety of real-world applications.
  • Cement replacement levels of up to 35% (slag, fly ash, silica fume, pozzolan) showed no impact on sensor accuracy.

DOT Project Highlights

Consistency of REBEL vs Sensor

Indiana Department of Transportation (INDOT)

I-69 & I-465 Paving Projects (Indianapolis)

  • REBEL Sensors were within 15% of cylinders at all ages.
  • Sensors showed <2.5% variability in readings across multiple placements, improving consistency over traditional methods.
  • At I-465 Bridge Deck, core samples at 32 days confirmed sensor readings were within 5% of expected strength.

Fort Wayne I-469 Bridge Deck

  • REBEL Sensor readings were within 4.7% of core samples taken at 16 days.
  • This high accuracy makes REBEL an effective tool for real-time quality assurance.

California Department of Transportation (Caltrans)

I-10 Paving (Los Angeles)

  • Four sensor groups were placed in different sections (bottom pavement, middle pavement, and beam molds).
  • Lab-cured sensors were within 2% of 42-day core samples, demonstrating their reliability in diverse curing conditions.
  • Field-cured sensors tracked within 6% of cylinders, ensuring strength assessments were accurate for real-world conditions.

US-50 Paving (Sacramento)

  • Sensors, cylinders, and cores were compared at multiple testing ages (1, 3, 7, 28, 42, and 59 days).
  • Five out of six core samples broke lower than expected, but sensors and cylinders showed higher, more realistic strength values.
  • Sensor variability was significantly lower than cylinder testing, improving the consistency of results.

Colorado Department of Transportation (CDOT)

I-25 Paving (Colorado Springs)

  • Sensors were within 15% of cylinder strength across all testing ages.
  • Pavement sensors provided more reliable readings compared to separately cured beam samples, proving their superior in-place accuracy.

Denver Airport Paving

  • Cylinders showed 28-day strength reaching 4,500 psi, but REBEL Sensors indicated this strength was achieved by Day 5.
  • This early strength insight could allow airports to reopen runways faster, reducing downtime.

Texas Department of Transportation (TXDOT)

SH-130 Road Patching Trials (Austin)

  • TXDOT tested REBEL Sensors in eight patching projects over two months.
  • The goal was to accelerate traffic opening by reducing reliance on cylinder break tests.
  • Across all patches:
    • REBEL Sensors had 12.2% variability, compared to 27.9% variability in cylinder tests.
    • Traffic opening times were predicted at least one hour earlier than cylinder breaks in most cases.
    • In one extreme case, sensors detected safe opening conditions 44 hours earlier than cylinders.

City of Manchester Paving (New Hampshire)

  • One sensor was placed in pavement for validation against cylinder breaks.
  • Sensor readings were within 6% of cylinder breaks at 7 days, proving strong correlation with traditional methods.

The Future of Concrete Testing

Wavelogix’s REBEL Sensors have demonstrated their potential to become a new industry standard in DOT projects. By eliminating the need for maturity curves, reducing variability, and accelerating construction timelines, these sensors provide safer, faster, and more cost-effective solutions for infrastructure development.

With successful trial deployments across 17 states, DOTs can confidently integrate real-time strength monitoring into their workflows. As agencies seek smarter ways to optimize road and bridge construction, REBEL Sensors offer a proven path forward.

🚀 See the full test results and project details here.