Transforming concrete training: how ForgeFX creates VR training solutions
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.Challenges in traditional trainingSomero 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.Technical features that boost realismUnity’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:Unity Cloud’s exception reporting provides actionable stack traces, aiding QA and issue tracking with minimal manual intervention.For performance, we rely on Unity’s CPU and GPU profilers to diagnose bottlenecks and optimize frame rates, ensuring smooth and responsive VR experiences.These tools guide us in identifying and addressing inefficiencies, particularly in physics calculations, to maintain seamless interaction and reliable simulations.XR Interaction Toolkit (XRITK) enhances the immersion and operational effectiveness of the Somero Training Simulator with an intuitive, cross-platform solution that simplifies virtual interactions. By using XRITK to manage the VR Rig, we enabled support for controllers and advanced hand-tracking features on Meta Quest 3 to create a seamless, responsive training environment that maximizes trainee engagement.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.)We utilize Unity Terrain to realistically render concrete surfaces, blending textures to reflect various finishes and consistencies throughout the pour. A Unity job is deployed to offload calculations for our custom concrete simulation which determines how the concrete colliders like the plow or vibrator impact the smoothness or roughness of the concrete as well as push and pull concrete around the surface. We have “rough” and “smooth” textures, with rough being the default and to set an alpha value for how much smooth texture we should be showing at each point on the terrain’s height map.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.
Customer feedbackAt 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.Case 1 – Non-user employees took the VR training and were able to successfully demonstrate use of the machine.Case 2 - Involved non-users who took the training, and survey results indicated they were confident in operating the machine.Future plans for the simulatorMore effective trainingThe 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 reachBy 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 lessonsAs 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.Experience the future of training today. Explore how Unity Industry can elevate your team's expertise while streamlining your operations.
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