ConcreteWorks | Summer 2013

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A L A BA M A CONCR E TE I NDUS TRIES ASSOC IATION M AGAZ IN E | SU M M E R 2013



TABLE OF CONTENTS | SUMMER 2013 ConcreteWorks is a publication of the Alabama Concrete Industries Association and features articles and photographs pertaining to product applications, educational opportunities, as well as innovative construction techniques impacting the industry. Please email rlindsay@ alconcrete.org with any comments regarding featured articles in ConcreteWorks or to suggest a story idea for a future edition. Rebecca Lindsay,

Art Director & Editor

John Sorrell, Editor

Jennifer Kornegay, Writer

2

At Barber Marina, considerable amounts

16

of concrete are proving once again that it

Alabama/Georgia border is using

is the go-to material when a project calls

concrete in a truly unique way to create

for the strength and durability to stand

an attraction that has nature lovers,

up to harsh environmental elements and

sporting enthusiasts, businesses and

severe weather.

local leaders excited. (ON THE COVER)

6

Concrete block is versatile to be sure,

22

but the talented students participating

avoided, and with some basic guidelines

in the ACIA’s annual Student Masonry

in place, contractors can greatly reduce

Competition each year continue to prove

the chance of having color variability.

Solid Ground

Don’t Reinvent the Block?

Rolling Under the River

A project recently completed on the

Color Consistency in Masonry Mortar

Color issues in masonry mortar can be

this. The 2012 winning project took the top www.alconcrete.org www.mysaferoom.org

prize for using block in an innovative way without trying to reinvent the material.

10

Most architects see their work as more

26

passion than profession, and Hal Gandy’s

for ready mixed concrete? This article

career path proves that first loves are

highlights industry standards and

hard to leave.

requirements.

Perfect Fit

Acceptance Test Reports for Ready Mixed Concrete

Who should get acceptance test reports


PROJECT SPOTLIGHT

At Barber Marina, considerable amounts

guests, race drivers and everyone who

into everything he does; everything he does

of concrete are proving once again that it

enters the park with a “best-of-the-best”

is top-notch, and is done right.” And doing

is the go-to material when a project calls

experience. It is no different at the marina, a

his marina right called for massive amounts

for the strength and durability to stand

project that was in the works for three years

of concrete — well over one million yards

up to harsh environmental elements and

before it was done. A long, winding drive

— in almost all of its various forms. Poured

severe weather.

off a county road weaves through stands of

concrete, concrete beams, concrete block

pine trees. If you look closely, you’ll see huge,

and concrete pavers are all used to great

In the spring of 2008, the Barber Marina

quite lifelike dinosaur sculptures peeking out

effect in the marina, and Ingram explained

opened in Elberta, Ala., on Bay La Launch

of the woods, as if they were going about

why the material is practically everywhere

on the Intra-coastal Waterway just north

their daily business. A replica of Stonehenge

you look. “The reason we went with so much

of Orange Beach. It takes its name from

is currently going up in a clearing. And

concrete is simple: It is strong, durable and

its owner, George Barber, the same man

a giant metal spider greets you near the

will last,” he said.

who built the Barber Motorsports Park

parking lot. These whimsical touches are a

and Barber Vintage Motorsports Museum

Barber signature and evidence of his desire

In one application, poured concrete helps

outside of Birmingham. Anyone who has

to always get people talking.

protect the marina’s main residents. At

visited the motorsports park knows how

any given time, it may house up to 375

creative and committed Barber is: creative

“Mr. Barber is a true visionary,” said Matt

boats in dry storage, and there are 175

in his use of large-scale modern art pieces

Ingram, an engineer and the marina’s

wet slips. Being on the coast, the marina

at a racetrack and committed to providing

general manager. “He puts a lot of thought

is responsible for keeping its clients’ boats


THE REASON WE WENT WITH SO MUCH CONCRETE IS SIMPLE: IT IS STRONG, DURABLE AND WILL LAST INTERIOR OF BOAT STORAGE AT BARBER MARINA | Elberta, AL

SUMMER 2013 3


PROJECT SPOTLIGHT

(many of which are worth hundreds of

The pad adjacent to the area where boats are

The concrete floating dock system does

thousands of dollars) safe in the event of

lowered into the water depends on concrete

more than just look pretty though. This

a big storm. When a hurricane threatens

for its strength. Mammoth boat lifters driving

specific type of concrete dock is renowned

the area, boats in the boatyard are tightly

over it day in and day out mean the space

for its durability and low life-cycle costs as

secured via cables to metal rings attached

has to be able to constantly support heavy

evidenced by the fact that there are nearly

to a four-feet wide, two-feet thick concrete

loads. Concrete pilings going down 60 feet

20 million square feet of them installed over

strip on the ground. “We know that concrete

into the water also successfully support the

the last half century. Thanks to concrete

is not going anywhere,” Ingram said.

continual use of heavy machinery.

being the major material, they do not rot,

Across the parking lot from the boatyard, a

Ingram is particularly proud of the marina’s

and environmentally friendly, all of which are

79,200-square-foot dry storage building sits

floating dock, also made using concrete.

important attributes for structures down

on a 14-inch-thick concrete slab with steel

“It fluctuates with the tide,” he said. “It is a

on the Gulf Coast. The concrete surface is

reinforced fibers, and its frame is supported

unique system.” The surface of the dock is

safe, as it is finished to be non-skid. Plus,

by various sizes of concrete beams.

made of large concrete form modules filled

concrete’s natural fire-resistance can lead to

“The dry storage is our most heavily used

with foam and then connected with rods.

lower insurance costs.

building, so it has to be really strong; it like

“The concrete here gives a nice, clean look,

everything else on property was constructed

which is a hallmark of Barber’s projects,”

Walkways and outdoor areas around the

to withstand a hurricane.”

Ingram added.

docks and the marina’s office and dock

burn or corrode, and they are non-polluting

DOCK AT BARBER MARINA | Elberta, AL


PROJECT SPOTLIGHT

shop were constructed with concrete

service is one of our main offerings,” he said.

pavers in two contrasting shades of gray,

“We live up to what we promise.” Knowing

again, to create the clean style that Mr.

the importance they place on meeting and

Barber is always after.

exceeding expectations, it is a good bet that Ingram, Mr. Barber and everyone at

Finally, split-face concrete block is used for

the marina expect the same level of service

several retaining walls around the property.

from anyone and anything they work with.

Ingram did some of the wall construction

Yet another reason to choose concrete:

himself. “I love being hands on, but working

Time after time, in myriad situations, it has

with concrete block in the South Alabama

shown it can deliver. And at Barber Marina,

summer heat can be taxing. It was a labor-

the proof is all around.

intensive process, but well worth it,” he said. “It looks great, and because it is concrete,

TOP: Concrete pavement is well suited for the heavy loads of the crane and boats. BOTTOM LEFT: The use of concrete for the piers requires little maintenance for

we know it will stand the test of time and the

Barber Marina

elements down here, just like the rest of the concrete we used.” Ingram stressed that Barber marina prides itself on taking care of its customers. “Stellar

SUMMER 2013 5


STUDENT PROJECT SPOTLIGHT

Don’t Reinvent

the Block


STUDENT PROJECT SPOTLIGHT

Picking & Choosing The

winners

of

the

Student

Masonry Competition were chosen by a panel of three judges that included Professor Emeritus Gaines Blackwell,

Auburn

University;

Assistant Professor Robert Brooks, Louisiana

Tech

University;

It’s an old saying, but true nonetheless: The

the first and second place winners and two

best way to learn is to do. That’s the idea

honorable mentions.

behind The Alabama Concrete Industry Association’s

annual

Student

Masonry

Each student’s competition project was

Competition. The event challenges third-

actually part of a larger studio project

year students in Auburn University’s school

they were already working on. They

of Architecture, Planning and Landscape

were instructed to select a portion of

Architecture to design a project that makes

these projects to submit for judging that

effective use of masonry block. Thirty-nine

exemplified an interior and/or exterior wall

third-year architecture students participated

condition and then present a detailed design

in the 2012 competition, and ACIA awarded

development that included the investigation

$2,500 for tuition and/or university fees to

of concrete masonry unit construction,

and

Alex Krumdieck of A+ I Design Inc. Birmingham and an Auburn University Adjunct Faculty member. The 2012 event was Krumdieck’s first year to serve as a judge, but he’s

B:

been teaching at Auburn’s Urban Studio for the last five years and is also an Auburn alum. “I attended Auburn and then did my master’s studies at Georgia Tech,” he said.

A:

Krumdieck has been practicing architecture

for

27

years

and

founded his own practice in 1995. His firm specializes in high-end residential projects as well as commercial office building and retail spaces that often use various forms of concrete. “Our practice is pretty diverse,” he said. His experience and expertise proves invaluable when it comes to teaching the next generation of architects and in judging things like the Student Masonry Competition. “I enjoy the judging process and teaching, and

A: First place award: C:

Michael Brud B: Second place award: Alexandra Buehning C: Third place award: Alex Hays

I plan to keep on teaching,” he said.

SUMMER 2013 7


STUDENT PROJECT SPOTLIGHT

assembly

processes,

structure,

finish

surface options for both exterior and interior conditions, innovative and traditional construction methods and custom masonry unit design applications. Each project design was required to be represented with a minimum of three drawings:

plan,

section

and

three-

dimensional (axonometric, perspective etc.), presented in a 20-foot by 32-foot format

E:

D:

oriented vertically. Sheri Schumacher, Associate Professor at Auburn’s school of Architecture, Planning and

Landscape

Architecture,

is

the

architecture studio coordinator for third-year undergraduate students, and along with Associate Professor Doug Burleson and Professor Tarik Orgen, helped organize and execute the competition. “We are so happy to have ACIA’s continued support of our program with this competition,” she said.

D: Honorable mention: Julia Long

E: Honorable mention: Kirby Tucker

She pointed to the importance of the very specific submission requirements. “The size

Gaines Blackwell and Robert Brooks as

Brundi’s own words on his presentation

limit in particular is very important since all

well as Alex Krumdieck of A+ I Design Inc.

best describe the concept and purpose

three studios participating in the competition

in Birmingham and an Auburn University

of his block wall. “The thirty-foot high wall

had different types of projects going,” she

Adjunct Faculty member. They set the bar

serves as a partition between two gallery

said. “The size limit means the judges were

high and were looking for some very specific

spaces that are opposites in scale and light

really comparing apples to apples.”

criteria: a design that exemplified tectonic

condition. The creation of voids between

understanding, innovative application and

each course of masonry would allow for the

exemplary use of architectural masonry units.

transmittance of light and visual interaction

Schumacher

also

outlined

how

the

competition benefits her students. “I can see

between

the

two

galleries.”

Various

that it allows students to understand more

Michael Brudi’s project fit the bill and earned

treatments of the edges of the bio-resin

about material resources in direct relation

him 1st place and $1,500 for tuition. “His use

used in the voids purposely contrast with the

to their studies,” she said. “The competition

of concrete masonry units was combined

“rough, tactile nature of the masonry” and

allows them insight from experts in the

with a transparent bio-resin sheet material,

encourage physical interaction with the wall.

industry, which they then apply to their

and the judges were really interested in his

studio projects.”

level of innovation and his clarity, which

Krumdieck explained what stood out in

was shown through his multiple scales,”

Brudi’s design. “I thought all the projects

The judges chosen each year are experts

Schumacher said. “It was apparent that he

submitted were pretty good, especially

in their fields representing architecture’s

had a firm understanding of how to realize

considering the rather short time they had

academic and professional communities,

his project as a whole.”

to come up with them,” he said. “But what

and this year the panel included Professors

impressed us in the winning project was


STUDENT PROJECT SPOTLIGHT

that it understood the idea and the inherent

the projects fell into two categories. “One

Schumacher agreed; she has been at

qualities of concrete block. It didn’t try to

included the projects trying to use it and

Auburn for 26 years and involved with the

completely reinvent it.”

understand it as it is; the other contained the

competition in the past. Every time, she’s

projects trying to use technology to change

impressed by how much the students

it,” he said.

learn. “What I thought was remarkable

Brudi’s project used block in a retaining wall, but by replacing the mortar joints with

was that in such a short period of

bio-resin sheet material, he created some

While each of the projects had some

time that students could gain so much

transparency in the structure. “That was

deficiencies, it was obvious to Krumdieck

knowledge about the concrete industry,”

unique because when most people think of

and the other judges that the students

she said. “And it is amazing to watch them

a block wall, they think of heavy and thick

worked hard. “I could tell they all did a lot

investigate innovative ways to use off-the-

and modular, but Brudi’s design challenges

of research into the material,” he said. He

shelf products.”

The competition allows them insight from experts in the industry, which they then apply to their studio projects. these pre-existing ideas. His wall was

stressed that this is why the competition

But it is not just the students who gain from

lighter,” Krumdieck said. “It is really a very

is so beneficial to the students’ education.

the competition. “Actually, their work and

simple idea and notion, but it really turned

“The focused application of using block that

research led them to find uses for concrete

the ideas about what block can do and be

comes with participating in the competition

masonry that allowed other students and

on their heads and was very successful in

helps them have better understanding of

even concrete industry representatives to

doing that.”

the material, and that’s always good,” he

better understand the vast potential of this

said. “Any time you can get more in-depth

versatile material,” Schumacher said.

Some of the other projects tried to reinvent

knowledge of what you are working with, for

concrete masonry units by applying new

an architect, that’s a great thing.”

technology; according the Krumdieck all of

ACIA 2012 Student Masonry Competition Winners First place award $1,500: Michael Brudi | Second place award $500: Alexandra Buehning | Third place award $500: Alex Hays Honorable mention: Julia Long | Honorable mention: Kirby Tucker

SUMMER 2013 9


A R C H ITE CT S P O T L I G H T

PE R FIT HAL GANDY

Fate can be quite forgiving; even when we take a wrong turn, we can still eventually end up right where we were always meant to be. Growing up with an architect father, Hal Gandy, principal at PH&J Architects in Montgomery, was exposed to the profession early and often. He even considered following in his father’s footsteps throughout his childhood and adolescence. But after high school, he ended up at Auburn University Montgomery (AUM) and earned his degree in business. Not long after graduation though, he realized the job options he was facing were not a good fit, and so he turned back to the aspirations of his younger self and enrolled in the architecture program at Auburn University. “I’d always been interested in architecture and had thought that I would end up being an architect, but by the time I got to college, I wasn’t really sure what I wanted,” he said. “I kind of fell into the business degree.” Today, 25 years later, it’s clear he made the right decision. The pleasure he takes in his


E RFECT

AR CHI TE CT S P O T L I G H T

profession is obvious in his easy manner

Montgomery and going to work with this

happy doing what he does. “The design

and smile when he talks about projects

father’s firm, PH&J. “I’ve never left,” he

process in architecture is a big part of what

he is proud of and the iconic works of

said, proving that once again, he’d made

I love about it,” he said. “I love the problem

architecture that inspire him. “Architecture

a solid choice. And working with his dad?

solving, having a set of parameters and

just drew me back,” he said. “I’d always

“I’ve truly enjoyed it,” he said. “I know

working to come up with a solution that

loved it, and when I realized that I wanted

some sons may not be able to say that, but

works within those parameters. There

to do something technical and tangible,

we really get along and work well together.”

is no better reward than when a client is

architecture fit that bill.”

John Gandy just recently retired. “I’ll miss

satisfied; when they are happy, the work is

him being here,” Gandy said.

all worthwhile.”

with an architecture firm in Opelika for

Gandy will keep on going without his dad

PH&J specializes in large-scale public

four years before coming back home to

around the corner, mainly because he’s

buildings:

York City, San Chappelle in Paris and the

between what’s real and what’s not get

First Christian Church in Columbus, Indiana,

blurred. It’s really interesting and timely.

After his second graduation, he worked

S ay H e llo

to H al Get to know Montgomery architect

schools,

churches,

banks,

by Eliel Saarinen. My taste is very eclectic. I like buildings that are dramatic either in form

CW: If you could have dinner with

or technological innovation but that maintain

anyone, dead or alive, who would it

a human scale to them.

be and why?

Hal Gandy a bit better through his

HG: Benjamin Franklin. I think it would

responses to our random Q&A.

be interesting to tell him about all the advancements

and

discoveries

in

CW: What are your hobbies?

science that have happened since

HG: I love to travel, particularly out West

he’s been gone and see his reaction to

to the desert states and the Rocky

today’s technology.

Mountains. I also run with a group of

CW: What is the one tool you can’t live

other architects and am looking forward

without?

CW: What’s your favorite food?

to running a half-marathon in Myrtle

HG: My pocketknife.

HG: My favorite foods kind of combine

Beach soon.

with my love of travel. I love any Italian CW: What’s the last book you read?

food, but I really love seafood and love

CW: What are your favorite pieces

HG: I’m just finishing a science-fiction novel

the Dungeness crab out in places like

of architecture?

called “REAMDE” about a guy who has

San Francisco and Monterey. I also like

HG: The Guggenheim Museum in New

invented this online game world and the lines

a good bottle of wine and some cheese.

SUMMER 2013 11


The design process in architecture is a big part of what I love about it

rsa headquarters | Montgomery, AL


AR CHI TE CT S P O T L I G H T

hospitals,

and

precast concrete panels on the exterior

said. “You can use a cheaper material at the

such. And in these projects, concrete is

government

buildings

as well as concrete pavers on the walks

outset and get a lower initial cost, but if you

the material that helps Gandy find those

in addition to the post-tensioned concrete

have to replace it 10 years later, you have

solutions he’s after. “Public buildings need

structural system.

not really saved money. But even for the

to last and last for a long time, and concrete

original cost, precast concrete in particular

is an enduring, durable material,” he said.

Gandy

also

likes

concrete

for

its

is usually very reasonable in price and is

Its inherent fireproof properties also make

flexibility when it comes to non-structural

more cost-effective and better fits budgets

it stand out. “When dealing with high-rise

applications. “We actually do a lot of precast

than many other materials.”

buildings particularly, its fire-resistance is a

panels and cornices, and use a lot of CMU

huge plus. If you used steel, you’d have to

and concrete pavers for decorative elements

Gandy

take extra steps.”

on projects, especially in the work we do for

sustainability, an aspect that was not really on

the state’s community college system,” he

the radar when he began his career but has

Gandy has also used concrete to overcome

said. “We’ve done many pedestrian walks

grown into a crucial element for many projects.

design challenges, one at a client’s specific

and paths on community college campuses

request. “We did the RSA headquarters in

composed of concrete pavers. Concrete

“Sustainability was almost a non issue when

downtown Montgomery, and that was big

is very versatile in this way, and concrete

I started, but now it is a big deal and really

foray into post-tensioned concrete,” Gandy

decorative elements really stand up and

has become second nature to us,” he said.

said. “The client really wanted us to do

hold up.”

“Concrete works well in that regard too.”

“Standing up” and “holding up” are crucial

TOP: Calhoun Community College Health

ACIA helped Gandy figure out the best way

components of a project’s long-term cost

Sciences Building.

to accomplish this, and the result turned out

and value, as Gandy stressed. “We always

perfect. “We produced 50-foot clear spans

want to provide the structure’s owner with a

on that project,” Gandy said. “I’m proud

material that will stand up to the environment

of that one.” That RSA building also used

and not require a lot of maintenance,” he

also

chooses

concrete

for

its

some larger spans without columns.”

SUMMER 2013 13


A R C H ITE CT S P O T L I G H T

Gandy pointed to a project he and his firm

An emphasis on sustainability is just one of

forms in a way that expresses the intent of

just recently completed — a LEED-certified

the changes to come about during Gandy’s

the design.”

project for Calhoun Community College

career. Another is the quality of concrete

in North Alabama that was able to re-use

available.

is

Another mentor was Jim Johnston, the

concrete components that were more than

much more attainable that it was 20 years

sole practitioner Gandy went to work for in

50 years old. “It was a simple concrete

ago,” he said.

Opelika right out of school. “I learned a lot

“Higher-strength

concrete

block and concrete frame building with a

about the business side of architecture and

pre-stressed concrete roof that had been

Gandy sees the current economy as a

about construction from him,” he said. “And

built in the 60s,” he said. “The concrete

challenge to architects, as it is for so many

I have to also mention a senior partner in

bones were still in great shape, so we

businesses today. Another change that can

my firm, Griff Harris; I’ve learned a lot from

were able to reuse the existing building

sometimes be a challenge is the shift in roles

him, too.”

and retained the roof structure, which was

when it comes to project management.

used to support a new metal roof system.

“We now see contractors trying to play a

Just as Gandy ended up in the same

We just refurbished it and repurposed it

larger part in project leadership,” he said.

profession as his father, it looks like at least

for its new life as the Alabama Center for

“Collaborative models for project delivery

one of his two sons will be working in the

Excellence in Clean Energy Technology at

are becoming more prevalent. That is not

same industry. “My oldest son Alex has just

the community college.”

necessarily a bad thing so long as the public

graduated from Auburn with his degree in

health, safety and welfare are protected

building science and is going back to school

Even the existing concrete floor that

along with the Owner’s interests. On public

get his master’s degree in design build,”

was soiled with 40 years of dirt and oil was

works projects the tax payers’ interests must

Gandy said. His younger son Michael is

easily transformed by being stained and

be protected, which is nearly impossible

attending AUM. But Gandy is not putting

polished to provide another 40-plus years of

to do unless construction contracts are

pressure on either to be or do a certain

service. Other concrete elements included a

competitively bid.”

thing. “They’ll figure out where they need to

new, extensive concrete paver system that

be,” he said. Just like their dad did.

was part of a pervious system designed to

Despite spending more than 20 years as an

move storm water into the ground and keep

architect already, Gandy feels that he is only

it from running off site.

about halfway through his career. “I still enjoy what I do, and I’m looking forward to helping

Had the frame been constructed from

carry the firm into the future and bringing in

another material all those decades ago,

young architects and mentoring them as they

steel for instance, Gandy may have found

grow in the profession,” he said. Enjoying the

some deterioration or a part of the structure

mentoring process and camaraderie with

that would not work with the new loads.

fellow architects in all stages of their careers

“We didn’t have any of those issues with the

is one reason he serves on the AIA state

old concrete,” he said.

council’s executive committee.

Other sustainable strategies in the building

He expressed his appreciation to those who

included rainwater harvesting to minimize

helped guide him. “My father was certainly

the amount of water used when flushing

a mentor. One important thing he always

toilets; ground source geothermal heat

practiced was that the guiding principle

pumps for heating and air conditioning;

when it comes to design is appropriateness,”

solar water heating; high efficiency LED

he said. “You have to determine what is

light fixtures; recycling of construction and

appropriate for each project; the scale, the

demolition waste materials; and photovoltaic

materials, articulating the materials and

generation of electricity.


We always want to provide the structure’s owner with a material that will stand up to the environment and not require a lot of maintenance

ALABAMA CENTER FOR THE ARTS | DECATUR, AL

SUMMER 2013 15


PROJECT SPOTLIGHT

R ollin G U nder the


PROJECT SPOTLIGHT

The thrill of paddling over and through

Phenix City, Ala. “It is going to be great

hotel tax revenues and create new jobs. Two

rushing rapids on a fast-flowing river is one

for both cities,” Senior Project Manager

whitewater outfitters were recently chosen

that more and more people are looking

with Scott Bridge Stephen Summers said.

to provide access to the course, one in

to experience. Plenty of the Southeast’s

Now completed, the 2.5-mile-long course

Columbus and one in downtown Phenix City.

abundant rivers provide exciting whitewater

is the longest “urban whitewater” course

opportunities naturally. But now, Scott

in the world, and its class 1 to class 4

It all began in 2010 when city leaders in

Bridge Company, on behalf of the Army

rapids provide a truly unique recreational

both government and the private sector in

Corps of Engineers and Uptown Columbus,

experience for paddlers — whether they

Columbus announced the Chattahoochee

is creating a manmade whitewater course

are in rafts, canoes or kayaks — from

River Restoration Project. The goal was

on a stretch of the Chattahoochee River

around the country and around the world.

to return the Chattahoochee River to the

straddling the Alabama and Georgia state

The project also benefits the area’s natural

place of prominence it once held in the

line that is currently moving at a much gentler

environment by restoring habitat for native

area, back when it provided transportation

pace. And they are using concrete to do it.

plants and animals. And then there are the

and power for industry, and this restoration

massive economic impacts, expected to

will make it an economic engine for the

The whitewater course runs right through

come for both Columbus and Phenix City

region once again.

downtown Columbus, Ga., and on toward

as visitors increase the cities’ sales and

SUMMER 2013 17


NO ONE HAS EVER DONE ANYTHING LIKE THIS BEFORE, IN AN URBAN, DOWNTOWN AREA

CONCRETE WAVESHAPERS FOR WHITEWATER COARSE | PHENIX CITY, AL


SUMMER 2013 19


PROJECT SPOTLIGHT

The section of the river that was transformed

Scott Bridge got started on this project in

in an urban, downtown area,” Summers

is dotted with old mills, several of which

September 2011, and Summers explained

said. “Other projects like this have had the

depended on two area dams to operate.

the role concrete is playing. “We have

luxury of dams that can cut the flow of the

These dams changed the natural course of

reconfigured the placement of existing

water off. But here, we are dealing with a

the river, and the whitewater course project

boulders to re-contour the bottom of the

constant river flow. There are three states

tore them down and returned the flow to its

river and create the rapids, and we used

fighting over the water this river provides, so

original state for the first time since 1828.

concrete to grout the rocks together and

there is always at least some water coming

“We removed two old damns that were built

hold them in place,” he said. “Concrete was

through, and that has been a real hurdle, but

for local cotton mills,” Summers said. “One

by far the best choice due to its durability

one we have overcome.”

is over 130 years old, but it had to go; you

and its flowability.”

cannot whitewater raft over a dam.”

The project opened Memorial Day weekend. Summers said his company has never

“Everyone involved is really excited about

The course also features a wave-shaper

worked on a project like this before, and it

it,” Summers said. “And concrete has done

device to make it more challenging. A

took a few tries to get the concrete mix just

the job well. It has definitely performed up

pedestrian bridge from the Columbus

right. “We’ve never done anything like this

to our expectations.”

Riverwalk onto one of the islands in the river

before; it is really special,” he said. “We used

allows the public a spectacular view of the

several different mixes and settled on using

TOP: Group gathers to experience and watch

newly created rapids. “We refurbished the

a fiber mix to get it flowable. Some of the

the newly completed urban whitewater

14th Street Bridge and made it a walkway,”

grout has gone eight to ten feet deep, and

coarse near Phenix City, Alabama.

Summers said. “It is a great viewing area

some we had to do in layers.”

for folks to watch rafters coming through.” One challenge has been working on the project with water still in the riverbed. “No one has ever done anything like this before,


WE HAVE RECONFIGURED THE PLACEMENT OF EXISTING BOULDERS TO RE-CONTOUR THE BOTTOM OF THE RIVER AND CREATE THE RAPIDS close up of CONCRETE WAVESHAPERS | PHENIX CITY, AL

SUMMER 2013 21


PROJECT SPOTLIGHT

Color Consistency in

Masonry Mortar It does not matter how expensive or elaborate the project is, it can be ruined if the masonry mortar has variability in color. Even slight differences in the color can stand out, and may be the first thing a person notices when they see the project for the first time. Correcting these issues can be very expensive, and sometimes the only solution may be to tear it out and start over. Color issues can be avoided, however. There are some basic guidelines that masonry contractors can follow that will greatly reduce the chances of having color variability in the masonry mortar.


The sample panel is critical, because it will be much more representative of the masonry work

trussville CIVIC CENTER | Trussville, AL

SUMMER 2013 23


PROJECT SPOTLIGHT

Prior to Construction

manufacturers obviously try to keep their

be based on full bags of masonry cement.

Colors for the masonry units and the masonry

products

reasonable

Do not use a batch size that requires you

mortar will be selected prior to construction

tolerances, but their sources and processes

to try and split bags. The bags never get

by the owner and/or architect. They may

may change over time.

evenly split, and the left over portion may

consistent

within

be selected by viewing sample products,

get wet or contaminated. The amount of

color charts, or existing structures. However

Storage of Materials

masonry sand used for the mortar should be

they are selected, it is recommended that

Masonry units should be kept on pallets

in accordance with ASTM C 270 “Standard

new sample panels be constructed prior

and should be covered. This will help in

Specification for Mortar for Unit Masonry”.

to the start of the job with the actual jobsite

keeping the moisture content of the units

Sand should be measured in a one cubic

materials that will be used on the project. It

consistent. Variability in moisture content of

foot box to ensure accuracy from batch

should be constructed by the same masonry

masonry units is a common cause of color

to batch. A common, but inappropriate,

contractor that will be actually performing

variations in the mortar. Unless a masonry

method for measuring the sand is to simply

the work for the structure. The mortar should

unit is 100% saturated, it will draw water out

count shovel full’s as they go into the mixer.

be mixed in the same manner and batch

of the mortar into the unit. This loss of water

The use of a shovel to measure the sand

size that will be used for the project. The

in the mortar will affect the color. If there is

is not accurate or consistent and can result

mortar joints for the sample panel should

significant variability in unit moistures, then

in batches that do not meet the proportions

be the same types that are planned for the

there may be noticeable color differences in

outlined in ASTM C 270. The homebuilder,

project. Timing of the tooling of the sample

the mortar.

general contractor, or owner should demand

panel should be performed carefully. Sample

that a cubic foot box be used.

panels are small, and it may be tempting

Masonry sand should also be kept covered.

to tool the joints too quickly. The sample

This will help maintain consistent moisture

The amount of water required for the right

panel is critical, because it will be much

content and also keep out debris. Sand

mortar consistency will be apparent after

more representative of the masonry work

for masonry mortar is added to the batch

the first few batches. The water should

than anything else that may be seen prior to

by volume and moisture content affects

be measured out in a five gallon bucket or

construction. The brick and mortar samples

the volume. This change in volume due to

some other container that can be marked.

in a showroom may look quite different

moisture content is known as bulking. A

Adjustments to the water may have to be

once they are in an actual wall. This is not

given amount of dry sand will occupy more

made depending on the weather and/or

necessarily anyone’s fault, it is just a fact that

volume than the same amount of sand

how well the moisture content of the sand

materials and workmanship may vary.

will when it is wet. Maintaining consistent

is maintained. It is extremely important to

moisture will help to keep the sand content

try and maintain the mortar consistency

Delivery of Materials

per batch consistent. Variations in the sand

from batch to batch. Try and have the same

If it is possible, all masonry units and

content will affect water demand of the

person do all of the proportioning and mixing

mortar material should be purchased and

mortar and this may affect color.

for each batch. Have that person train one or

delivered to the project at once. This will

more other people to do it when he or she is

help ensure that materials are all from the

Bags of masonry cement should be

not available. Remember, consistency is the

same run and are consistent. This may not

delivered to the project on pallets, and they

name of the game to avoid color problems.

be possible on large projects, due to time

should remain on the pallets. The pallets

and storage constraints. If this is the case,

should be carefully covered with plastic

An option that can help eliminate variances

the manufacturer of the masonry units and

to keep the bags completely dry. Mortar

in mixture proportions is to use pre-blended

masonry cement may be able to store the

Proportions and Mixing

dry masonry mortar that is available from

same run of products at their site. You

a number of suppliers. The product is

want to be able to avoid a situation such as

Once construction begins, the name of the

proportioned according to ASTM C 270 and

needing 10 more bags of colored masonry

game is consistency. Do every thing you do

all that has to be added is water. It is usually

cement to go with 500 bags that were

the same, batch to batch, day to day. The

available in bags or 3000 lb bulk sacks.

produced three months before. Materials

mortar batch size that is used should always


PROJECT SPOTLIGHT

TOP LEFT: Masonry project in Orange Beach, Alabama highlights the importance of consistent color to the final product. Tooling of Joints

waiting for the proper jointing time. This is

solution that is to be used on the masonry

The final tooling, or striking, of joints,

why you can sometimes tell where one days

units and mortar should be done so in

can have a huge impact on the resulting

work ends and another starts. The end of

strict accordance with the manufacturer’s

color of the mortar. As with everything

the previous days joints are lighter in color

recommendations. Cleaning products that

else mentioned, consistency is the key.

because they were struck too early.

contain acid can damage the mortar and

The timing of this procedure is what is so

affect the color, sometimes drastically, if

important. If the joints are tooled to early,

Cleaning of Masonry

not used properly. Most of these products

when the mortar is still very plastic, a high

When it comes to cleaning masonry units,

are mixed and diluted, so close attention

water content paste may be pulled to the

the less you have to do the better. If the

must be paid to the proper proportions.

joint surface. This can result in a porous,

masons are careful during construction, they

The use of muriatic acid should be avoided.

light-colored surface. If the joint is tooled

can reduce the need for excessive cleaning.

Only used products specifically made for

too late when the mortar is stiff, the mortar

As mentioned above, tooling the joints at

cleaning masonry.

is not compacted, and there is friction

the proper time is critical to achieving the

between the metal jointer and mortar, and

correct color. It also has an impact on how

this can cause the color to be too dark. The

much mortar gets on the masonry units.

joint should be tooled when the mortar is

When joints are tooled too early, mortar

“thumbprint hard.” That is, hard enough to

can get smeared and splattered all over the

Summary of Key Points

allow an impression, but not too soft to push

units. The less they get on the units, the less

· Prepare sample panels

the mortar out of the joint.

they have to clean.

· Order enough materials for the job · Safely store sand and masonry

The masons have to be very careful with

There are numerous methods for cleaning

their joint timing. One common problem is

masonry units. The main interest here is on

· Be consistent in batching

cement

at the end of the day. The masons may want

color consistency, so the details of each

· Tool joints at the proper time

to strike the last remaining courses of work

method will not be discussed. The key

· Use extreme caution with cleaning

all at one time and go home, rather than

point regarding color is that any cleaning

solutions

SUMMER 2013 25


PROJECT SPOTLIGHT

Acceptance Test Reports for Ready Mixed Concrete W ho S hould G et T hem ? C olin L obo

The

is

for establishing their concrete mixture

entities increases their cost, although this

reasonably well established for quality

process

proportions and properties for new work

concern should be less of an issue with

assurance

and to provide this documentation in a

the widespread availability of electronic

submittal to the engineer of record.

communication. Some testing agencies

of

of

testing

ready

concrete

mixed

concrete

delivered to projects. The owner or his representative hires an independent testing

only provide failing strength test results to

and/or inspection agency to perform quality

To meet these requirements, it is essential

concrete suppliers to notify them that a

assurance functions during the construction

that the concrete supplier be provided ALL

problem exists. Clearly, this is undesirable

of the Work. Industry standards provide

reports of acceptance tests performed on

because if previous tests were provided and

requirements for the following:

the concrete mixtures delivered during the

a trend was observed, the failing test result

progress of a project. These test reports

could have likely been avoided.

• Qualification of testing agencies and

should be provided in a timely manner so

testing technicians;

that proactive action can be taken to ensure

Many concrete producers have established

• Frequency of testing;

that specified requirements for concrete,

relationships with local testing agencies to

• Standardized procedures for obtaining

especially strength, are not violated. When

ensure that test reports of all tests performed

low-strength problems occur, considerable

on their concrete are distributed to them.

time and money is expended to evaluate

Web-based test reporting systems also exist

the cause and to take corrective action. It is

whereby test reports posted can be accessed

thereby beneficial to all parties to minimize

by pertinent project team members.

samples and performing tests; • Acceptance criteria for fresh and hardened concrete tests; and • Referee testing and criteria for tests that fail to meet the acceptance criteria.

the risk of low-strength concrete. Important revisions were approved in the

Standards require the concrete supplier

Why is the distribution of test reports an

ACI 318-11 Building Code for Structural

to maintain a quality control plan and to

issue? Some testing agencies do not

Concrete to address issues related to testing

take steps to respond to situations when

provide test reports to concrete suppliers

of concrete and reporting of results. Section

test results are trending towards potential

because they believe these reports should

5.6.1 of ACI 318-11 has been revised to

noncompliance. Prior to a project, the

only go to the entity that contracted with

address distribution of test results. The

supplier is required to use a complete test

them for the testing services. Some believe

following is the excerpt from the code:

record from previous projects as a basis

that distribution of test reports to several


Many concrete producers have established relationships with local testing agencies to ensure that test reports of all tests performed on their concrete are distributed to them.

PRESSURE METER AIR TEST

SUMMER 2013 27


PROJECT SPOTLIGHT

All reports of acceptance tests shall

of the mandatory checklist items that needs

prevent delays in project schedules due to

be provided to the licensed design

to be completed to make this a complete

these evaluations.

professional,

concrete

specification is on the agency’s responsibility

producer, and, when requested, to the

contractor,

for submittal of reports to include timelines,

Colin Lobo, Ph.D., P.E., is senior vice president,

owner and the building official.

methods of delivery, and the distribution list.

engineering, at NRMCA.

The distribution list defined in the contract The following is the discussion in the

with the testing agency should include the

References

commentary to this code provision:

concrete supplier and all the other parties

ACI 301-10, Specifications for Structural

listed in ACI 318-11.

Concrete. Farming ton Hills, MI: American

The code requires testing reports to be

Concrete Institute (www.concrete.org).

distributed to the parties responsible for

Another revision to ACI 318-11 regarding

ACI 311-09, Specification for Ready Mixed

the design, construction, and approval of

testing is that it now requires testing agencies

Concrete

the work. Such distribution of test reports

to comply with ASTM C1077, Standard

Hills, MI: American Concrete Institute (www.

should be indicated in contracts for

Practice for Agencies Testing Concrete and

concrete.org).

inspection and testing services. Prompt

Concrete Aggregates for Use in Construction

ACI 318-11/ACI 318R-11,

distribution of testing reports allows for

and Criteria for Testing Agency Evaluation.

Requirements for Structural Concrete and

timely identification of either compliance or

This has been a requirement in ACI 301,

Commentary. Farming ton Hills, MI: American

the need for corrective action. A complete

Specification for Structural Concrete, and

Concrete Institute (www.concrete.org).

record of testing allows the concrete

ASTM C94, Specification for Ready Mixed

ASTM

producer to reliably establish the required average strength fcŕ for future work.

Concrete. It is now a code requirement.

Ready Mixed Concrete, Annual Book

ASTM C1077 establishes quality systems

of ASTM Standards, American Society

for testing agencies, requiring labs to have

of Testing Materials, Volume 4.02. West

This commentary highlights the fact that

periodic inspections of their procedures and

Conshohocken, PA: ASTM International

distribution of test results is important not

equipment, verifies qualifications of testing

(www.astm.org).

only to the current project, but also to

technicians and requires laboratories to

ASTM C1077-12, Standard Practice for

quantify the level of quality control (measured

participate in proficiency sample testing.

Agencies Testing Concrete and Concrete

by the standard deviation of strength test

Proficiency sample testing allows labs to

Aggregates for Use in Construction and

results) of the concrete supplier. While a

compare their results to those of other

Criteria for Testing Agency Evaluation,

component of this variability is attributed

labs when the same material is tested.

Annual Book of ASTM Standards, American

to testing, a measure of standard deviation

The validation that a laboratory complies

Society

allows for continuous improvement and

with ASTM C1077 is obtained through an

4.02. West Conshohocken, PA: ASTM

facilitates better optimization of concrete

accreditation program provided by several

International (www.astm.org).

mixtures at reduced cost for future projects.

national and local entities. ACI 318 does not

A complete test record from past projects is

require the testing agency to be accredited.

This article first appeared in the Spring

required for use as the basis of a submittal

ACI 311.6 goes this extra step to require

2013 edition of Concrete InFocus and is

for future work.

testing agencies to be accredited and lists

published here with the permission of the

acceptable accreditation programs.

National Ready Mixed Concrete Association

The engineer of record or other owner’s

Testing

Services.

C94/C94M-12,

of

Testing

Farmington

Building

Code

Specification

Materials,

for

Volume

(U.S.). Further reprints are prohibited. All

representative should ensure that the

If

distribution list of test reports includes the

it is imperative that information on the

someone

manufactures

a

product,

entities listed in ACI 318. ACI Committee 311

evaluation of the product be provided to the

publishes ACI 311.6, Specification for Ready

manufacturer. This is not only in the interest

Mixed Concrete Testing Services, which can

of the manufacturer but also to the owner

be used by the owner as part of the contract

who uses the product. Avoiding problems

for testing and inspection on projects. One

with test results will save time, money and

rights reserved.



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