When construction sites start up in spring, the number of cycles at the truck scales in quarries, gravel pits and concrete plants often increases noticeably, precisely when breakdowns hurt the most. In practice, it is rarely “mysterious” defects that cause problems, but typical winter consequences: Mud, grit and moisture collect in the scale pit, dust and abrasion clog joints and built-in parts, and the freeze/thaw cycle leaves small but decisive marks on the mechanics, foundations and cable routes. If you consistently clean, check and adjust once in spring, you can ensure that the scales remain stable, precise and available during the peak season – even when throughput is high.
Typical winter sequences in quarries, gravel pits and concrete plants
In the construction industry in particular, several stresses act simultaneously. Abrasive cement or gravel dust is deposited everywhere, and in winter road salt and chlorides accelerate corrosion on metallic parts. The result often only becomes apparent in the spring: measured values drift, the display stabilizes more slowly than usual, axle loads appear implausible or faults suddenly only occur “sometimes” – classically in the case of moisture in junction boxes or damaged cables and plug connections.
Cleaning and mechanical freedom of movement: the basis for precise weighing
The most important lever at the start of the season is a combination of professional cleaning and targeted maintenance. It’s quite simple: a scale can only measure correctly if it is mechanically free. Stones in joints, encrusted caking or muddy areas on supports cause parts of the bridge to “carry along” unintentionally or become distorted. This results in jumps, drift or reproducible deviations in certain vehicle positions. Thorough cleaning of the scale surface, joints, lateral areas and – in the case of pit scales – the entire scale pit often provides the solution. It is important not to use force to clean sensitive components: We recommend not using aggressive high-pressure cleaning on sensitive areas such as load cells and built-in parts in order to protect seals, cable bushings and the installation situation.
Check drainage: Protection against flooding of electronics during spring rains
Drainage is even more crucial in spring. After the winter, drains, gutters or drainage systems are often blocked. And when the typical spring rains start, water builds up where it doesn’t belong: in the scales pit, in cable ducts or near junction and summation boxes. Standing water is not only a corrosion driver, it is also a real danger for electronics, terminals and contacts. The spring check should therefore always focus clearly on the drainage system: Are drains visibly unblocked? Is an existing pump working reliably? Are there areas where water remains although it should drain away? A short, controlled water test can quickly show whether a drain is really draining and save you trouble later if there are failures after heavy rain in the middle of the season.
Junction boxes, cables and tightness: the most common cause of sporadic faults
Once the scales are clean, the next step is to look at the “invisible” causes: Connection areas and cable routes. In quarries and concrete plants in particular, cables are subject to high mechanical loads: vibrations, abrasion and occasionally crushing or chafing. Added to this are moisture and temperature changes, which promote condensation in poorly sealed transitions. In practice, it is often loose screw connections, small leaks or corroded plug connections that lead to sporadic faults. Checking the tightness and fit of cable glands in spring, inspecting cable conduits and reworking critical points prevents the typical “comes and goes” faults that become particularly expensive at peak times.
Foundations, subsidence and ramps: when the surroundings “cooperate”
Another point that is often underestimated in the construction industry: Settlements and the mechanical geometry around the scales. Heavy vehicles, changing load distributions and frost-related movements can cause minimal changes to ramps, approach areas and supports. This does not have to be dramatic, but it is enough to reduce free movement or create tension. This is why spring maintenance always includes a check of the mechanical situation: Does the bridge run freely without touching anything? Are there any contact points that did not exist the previous year? Are the joints even, are the boundaries correct and are there any signs that the foundations or adjacent components are “working”? Recognizing such issues early on makes it possible to plan for the later peak season.
Weighing software and weighing station IT: updates, function check and small batteries with a big impact
If the mechanics and electronics fit, it is often the digital chain that determines smooth operation. PC-based weighing systems in particular benefit from the fact that updates do not run “on the side”, but are installed in a planned maintenance window. An unplanned restart due to automatic updates can noticeably slow down throughput at the wrong moment. It is therefore advisable to have a defined spring date on which operating system and weighing software updates are installed and then tested: Does the application start stably, do user rights and interfaces fit, do printers, scanners, traffic lights, remote displays, barriers, RFID or ERP connections work reliably?
And then there are the little things that suddenly become big during the season: weak batteries in remote controls, a scanner that only connects sometimes or a UPS whose batteries have lost capacity. Checking these peripherals and replacing wearing parts in good time prevents downtime, which is disproportionately expensive at peak times.
Sensible modernization for the start of the season: protection, diagnostics and more automation
If your scales are regularly exposed to mud, dust and moisture, targeted optimizations are worthwhile. Improved cable protection in particularly stressed areas, higher-quality seals at critical transitions or more modern junction boxes with better moisture protection often bring lasting peace of mind. Remote maintenance capability and diagnostics via status messages or error codes are also a real advantage in practice: many faults can be localized more quickly, and the difference between a “10-minute solution” and “travel + standstill” quickly becomes noticeable in summer. Those who also digitize weighing processes – for example with automated processes, license plate recognition or end-to-end digital delivery bills – not only gain convenience, but above all throughput and traceability.
Recommendation: Service window in March/April before the peak season starts
The bottom line is that the spring check is less a single measure than a strategy: you take the risk out of the peak of the season. The best time for this is the window of time before the first ramp-up, typically in March or April. Then the winter traces are visible, operation is even easier to plan than in summer operation, and you can bundle cleaning, drainage checks, leak and cable checks, mechanical clearance as well as software and periphery tests into one clean maintenance appointment. The result is direct operational reliability: precise weighing, fewer faults, fewer queries. And a scale that simply works throughout the summer.
We have provided you with a checklist for your vehicle scales check, which you can carry out yourself:
More safety with the ESSMANN scale construction professionals
If you want to be absolutely sure that your truck scales are in tip-top condition, book a service appointment with our scales experts now. Our experienced and well-trained service technicians will carry out the spring check for you – together with your employees, who will also learn which signs to look out for.
Spring check carried out and defects discovered? Even then, we will be happy to take care of your vehicle scales. Talk to us!
ESSMANN | Technical Service
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