Somero Enterprises, a global leader in concrete leveling technology, partnered with ForgeFX to revolutionize operator training with an immersive virtual reality (VR) solution for their S-22EZ Laser Screed® machine. For concrete professionals, this immersive training solution reduces high training costs and logistical challenges, while equipping operators with a hands-on, safe, and engaging learning environment. By leveraging Unity’s technology, and tools such as the XR Interaction Toolkit, manufacturers like Somero have the power to streamline training processes, improve operator proficiency, and reduce operational constraints.
Imagine building a skyscraper without a solid foundation — finding skilled talent in the construction industry today can feel just as daunting, with labor shortages threatening to bring projects to a grinding halt.
According to the Associated General Contractors of America, 2024, 79% of construction firms today report difficulty in finding skilled workers, impacting project timelines and cost. The aging workforce also contributes to this gap, with 41% of the workforce projected to retire by 2031 as per the National Association of Home Builders.
The need for smart solutions to skill shortage in the construction industry has never been greater.
Somero specializes in laser-guided concrete screeding equipment, including the S-22EZ Laser Screed® machine, a key tool for achieving high-quality, level concrete floors. Their goal was to create a VR simulator that would train operators safely and efficiently while also addressing their global capacity constraints of high travel costs, machine wear, and logistical limitations. Trainees needed experience in handling controls and understanding spatial dynamics without the need for physical machinery.
Mastering the art of concrete leveling requires more than just tools—it demands the transfer of hard-earned skills honed over years of physical practice. Dave Raasakka, Somero VP of Global Customer Support, shares, 'Concrete is a perishable product. Once it hits the ground, you have an hour to get it done. Otherwise, you get into trouble.'
Training for heavy machinery like the S-22EZ Laser Screed® machine traditionally requires extensive physical resources, such as the machinery itself, specialized equipment like laser transmitters, and a dedicated training area outfitted with appropriate concrete forms and pour conditions. These real-world scenarios often come with high costs, including wear and tear on machinery, and can be hindered by factors like equipment availability, adverse weather conditions, or risks such as slips and falls while accessing elevated components. With six global service centers and hundreds of trainees annually at the Somero Concrete Institute, Somero required a scalable solution to address these logistical, financial, and safety challenges effectively.
Somero turned to ForgeFX Simulations for an alternative training solution to deliver consistent, high-quality learning experiences that addressed their needs and solved their constraints. We faced the complex task of designing an immersive training simulator that accurately replicated the operation of the Laser Screed including capturing the tactile feedback and visual realism needed to mimic the experience of working with the actual machine. Powered by Unity, the solution replicates the S-22EZ’s complex controls and provides trainees with a realistic, hands-on experience in a virtual environment, eliminating the need for physical equipment during the learning process.
Unity’s robust XR tools power the S-22EZ Laser Screed® VR simulator, enabling precise replication of equipment behavior in highly realistic immersive 3D environments, such as:
These tools guide us in identifying and addressing inefficiencies, particularly in physics calculations, to maintain seamless interaction and reliable simulations.
This setup minimizes development time by standardizing interaction components like snap turning, teleportation, and object manipulation, and ensures the simulator remains adaptable to future hardware and software updates.
Unity’s Job system enables us to realistically simulate concrete on a secondary thread without impacting the main thread’s performance. Using trigger colliders as bounding boxes, we defined factors that can influence the concrete both intentionally and unintentionally, such factors caused by the screed head or machine tires. These have no rigid bodies and their layer mask for collisions is set to include none, so minimal work is being done on the main thread. The job system allows for up to four simultaneous threads to run on the standalone Quest headsets without impacting the main thread performance. (On the main thread we track positions of bounding boxes that represent pieces of the machine that can affect the concrete.)
On the main thread, there are two quick functions to update the terrain to match the heightmap and alpha map data the jobs write to. Together, these systems reinforce an immersive virtual environment where users experience the visual and tactile nuances of working with concrete, enhancing training effectiveness and user engagement through a faithful reproduction of complex construction activities.
At the conclusion of the pilot phase, Somero conducted two case studies that showed improved operator skills on the 22EZ Laser Screed® after completing the VR training.
More effective training
The Somero S-22EZ Advanced Laser Screed® VR Training Simulator represents a leap forward in construction training technology. By addressing the challenges of traditional training methods this immersive training platform offers unparalleled precision, accessibility, and engagement for operators worldwide. With the ability to simulate complex real-world scenarios, reduce environmental impact, and enhance skill retention, the simulator not only prepares operators for optimal performance but also positions Somero to achieve greater efficiency and ROI.
Expanded market reach
By providing distributors with the ability to give interactive demonstrations of their large-scale machines remotely, the simulator promises to positively impact Somero’s global market penetration. Somero has the potential to accelerate sales cycles, improve customer decision-making, and expand their global footprint—all while reducing the logistical costs and environmental impact associated with traditional equipment showcases.
Beyond structured lessons
As Somero conducts further testing on Phase 2 of the simulator, the roadmap for Phase 3 is being envisioned. Potential areas of focus include advanced concrete simulation that replicate factors like varying slump levels or drying stages, and sandbox-style lessons that allow trainees to freely interact with virtual machinery beyond structured lesson steps. As ForgeFX and Somero continue to innovate on the Unity platform, the possibilities for transformative training experiences in the manufacturing industry are endless.
Interested in learning more about this story? Check out our webinar with ForgeFX and Somero Enterprises here.
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