From ControlNet to Ethernet: A Concrete Producer’s Journey to Network Resilience

The Situation

For a leading concrete producer operating multiple production lines across a large Midwest facility, reliable network infrastructure was essential for both safety and operations. The facility had long relied on a ControlNet architecture, but over time, the system approached the end of its viable life. Recognizing the risks associated with aging infrastructure, the customer initiated a multi-year modernization effort.

Rather than waiting for a failure to force reactive action, they chose to proactively upgrade their network and take control of the timeline. To execute this effort with precision and reliability, they partnered with Tri Tech Automation to transition to a modern EtherNet/IP network built on Rockwell Automation’s industrial Ethernet platform. To meet these constraints, the customer required not just field execution, but a partner capable of pre-engineering, building, and validating systems in a controlled environment, minimizing risk before arriving on site.

The Customer’s Need

By the time modernization began, several challenges had made the existing system unsustainable. ControlNet hardware had reached end-of-life and was no longer manufactured, eliminating a reliable path for spare parts. Fiber optic cabling in multiple areas was physically exposed and vulnerable to damage, increasing the likelihood of failure. At the same time, network performance had degraded due to aging media and limited fault tolerance, resulting in production slowdowns. Operators frequently attributed production issues to the network, which made accurate root cause analysis difficult and time-consuming.

The customer needed a solution that would not only replace outdated hardware but also improve reliability, restore confidence in operations, and eliminate unplanned downtime. Just as critical, the migration needed to be completed within tight shutdown windows without introducing risk or unexpected issues during commissioning. They required a partner who could deliver a disciplined, well-planned approach that minimized disruption while ensuring the new system would be scalable, supportable, and built for long-term performance.

The Tri Tech Solution

Tri Tech Automation approached the project through the Hidden Factory approach; a design-build methodology that brings engineering, panel fabrication, and system validation together in a controlled environment.

The project took the following path:

Development of Documentation
The engagement began with a comprehensive forensic audit of the existing ControlNet network. Every device, node, fiber run, and I/O connection was individually documented, evaluated, and mapped.

This process established a reliable baseline and enabled the development of a detailed, step-by-step migration strategy. The plan defined what needed to be replaced, in what sequence, with what hardware, and at what level of risk. This attention to detail ensured a fully informed and controlled execution approach.

Full Network Staging & Testing
Once the design was finalized, all hardware was procured and fully staged at Tri Tech Automation’s facility. The complete network and controls system, including switches, configurations, and Device Level Ring (DLR) topology, was assembled and tested in an environment that closely replicated actual plant conditions.

Factory Acceptance Testing (FAT) served as a critical risk mitigation step and included:

End-to-end configuration validation across all network components and PLC integrations
Benchmark testing of failover performance, ring recovery times, and redundancy behavior
Validation and refinement of disaster recovery procedures
Direct customer involvement and visibility into system performance prior to deployment

This rigorous staging process ensured that potential issues were identified and resolved weeks before installation, rather than during live production shutdowns.

Packaged, Labeled & Site-Ready Delivery
Following successful FAT, all equipment was carefully packaged and labeled by area, panel, and installation point. This level of preparation allowed installation teams to execute efficiently during shutdown windows, eliminating time lost to sorting, rework, or misidentified components.

Everything arrived on-site fully organized and ready for immediate deployment.

Deployment
With preparation complete, each phase of the migration was executed within a tightly controlled 12 to 24-hour commissioning window. Legacy ControlNet systems were decommissioned, the new EtherNet/IP infrastructure installed, and all devices authenticated against pre-tested configurations. Because of the extensive upfront validation, commissioning proceeded exactly as planned.

The Results

Tri Tech Automation successfully delivered a modern, resilient network infrastructure on schedule and without disruption to operations. In the words of the facility’s controls engineer, “In all the areas we have migrated, we don’t have these problems anymore — because it’s not failing anymore.” The project was completed with zero surprises during commissioning due to comprehensive pre-validation, and network-related production downtime was eliminated in all upgraded areas. The new system provided improved diagnostic visibility, including real-time insight into network health and performance, while also restoring access to readily available spare parts through standard Ethernet components.

Beyond the immediate performance improvements, modernization significantly increased operator confidence and overall system reliability. Enhanced network visibility tools gave operators greater awareness and control, while standardized configurations across all upgraded areas improved long-term maintainability. The project not only resolved existing challenges but also established a scalable, future-ready foundation, positioning the facility for continued expansion and ongoing optimization. The success was driven in large part by Tri Tech’s ability to design, build, and validate the system off-site, thus reducing uncertainty, accelerating deployment, and delivering a zero-surprise experience for the client.