Magnetic Technology Delivers Consistent Quality Stamped Concrete Design
30
January/February 2017
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Building a
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CONEXPO PRODUCT PREVIEW 52
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January/February 2017 | Issue 1, Volume 17
WHAT’S INSIDE
Cover Photo Credit: Nathan Padilla Bowen
Departments 4 Editor’s Letter 6 Legal Matters 8 Challenging the System 56 Foundation Q&A 66 The Last Placement
What’s Online
Cover Story
Read these online exclusive articles at www.ForConstructionPros.com/ concrete.
24 Building a Concrete Castle
A Sense of Place
Their home really is their castle.
A church plaza becomes something more through careful design and quality construction.
Features
Search: 12298774
12 Secondary Containment Project is Second to None ShotCrete Montana fine-tunes chemical refinery’s totally shot floor.
16 World of Concrete Post Show Product Round-up A compilation of new products exhibited at the World of Concrete 2017.
30 Magnetic Technology Delivers Consistent Quality Stamped Concrete Design Proline Concrete Tools’ Seamless Pattern Stamps provide decorative concrete contractors with an accurate and efficient way to produce a variety of stone-looking designs in the same time it takes to produce a seamless texture design.
36 Specification Guides: Grinders A compilation of technical information when choosing your next grinder.
44 Diamonds are a Concrete Contractor’s Best Friend Proper blade selection makes for a happy working relationship.
Paver Restoration: Hardscape Contractors Learn to “Seal the Deal” Application of premium cleaners and sealers to aging hardscapes is opening the door for new opportunities in paver restoration. Search: 12298780
16
48 Saw Blade Product Round-up A compilation of saw blades.
52 ConExpo Pre-Show Product Round-up
52
A compilation of products from companies scheduled to exhibit at the BIG SHOW.
60 Rehabbing Aging Concrete Wastewater Infrastructure Advanced polyurea coatings and liners provide strong, flexible waterproofing to bridge cracks and protect against future cracking deterioration.
44
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EDITOR’S LETTER Published by AC Business Media Inc.
World of Concrete was a
W
SUCCESS
ith the 2017 edition of the World of Concrete show now in the rear view mirror, I write this column thinking about how energized and upbeat both attendees and exhibitors were about the upward momentum of the industry. As I walked the show floor, both indoors and out, I felt a buzz in the air, that I can say, I haven’t felt in a few years. Representatives of the World of Concrete have reported the event drew 50,770 registered attendees and featured more than 1,455 exhibiting companies, it’s easy to feel upbeat. During my travels around the show, I was told by several exhibiting companies they were having a record selling show. Equipment and products were being sold off the show floor at levels not seen in a few years. Meanwhile, contractors told me their reasons for attending the show was to learn about new products and network with their peers. While others said they came because they were ready to make “big ticket” purchases to update their current fleet of equipment. Sounds like good news for contractors too. If you were unable to attend the show this year, worry not – we have a packed section of products Facebook.com/ ConcreteContractor
Advisory Board
Ryan Olson, Publisher/ Editorial Director ROlson@ ACBusinessMedia.com (800) 538-5544
featured at the show. Turn to page 16 to explore all of what we discovered at the show. Don’t forget to also visit, www.ForConstructionPros.com/ Concrete to see even more. There you will find a variety of products and company updates, but you can also visit the Video Network, http://www. forconstructionpros.com/media-center, where our editorial team interviewed leading industry experts about their products, services and in some cases industry issues. On another note, I’m happy to announce, the 2nd edition of the Concrete Polishing and Staining Conference will be held October 5-7, 2017 in Pittsburgh, Pa. If you’re a contractor who performs polished concrete work, you’ll want to attend to take advantage of first-class educational seminars and have the opportunity to visit with industry leading exhibitors. More information will be available mid- to late February at www.CPSConference.com.
Follow us @ Concreteinsider
Kim Basham KB Engineering Cheyenne, Wyo.
Jim Cuviello Cuviello Concrete Polished|Stained|Crafted Stevensville, Md.
Jim Baty Concrete Foundations Association Mt. Vernon, Iowa
Chris Klemaske T.B. Penick & Sons, Inc. San Diego, Calif.
Search: Concrete Polishing
Dennis Purinton Purinton Builders, Inc. East Granby, Conn.
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Published and copyrighted 2017 by AC Business Media Inc. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording or any information storage or retrieval system, without written permission from the publisher. CONCRETE CONTRACTOR (USPS 021-799, ISSN 1935-1887 (print); ISSN 2471-2302 (online) is published 7 times a year: January,/February, March, April/May, June/July, August/September, October/November and December by AC Business Media Inc., 201 N. Main Street, Fort Atkinson, WI 53538. Printed in the U.S.A. Periodicals postage paid at Fort Atkinson, WI, and additional entry offices. POSTMASTER: Send address changes to Concrete Contractor, PO Box 3605 Northbrook, IL 60065-3605 January/February 2017, Issue 1, Volume 17 One year subscription to nonqualified individuals: U.S. 1 year: $35, 2 years: $70. Canada & Mexico 1 year: $60, 2 years: $105. All other countries 1 year: $85, 2 years: $160 (payable in U.S. funds drawn on U.S. banks). Single copies available (prepaid only) $10.00 each (U.S., Canada & Mexico), $15.00 each (International). Canada Post PM40612608. Return Undeliverable Canadian Addresses to: Concrete Contractor, PO Box 25542, London, ON N6C 6B2.
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4 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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Ryan Olson, (800) 538-5544, ext. 1306 rolson@ACBusinessMedia.com Kim Basham, Jim Baty, Brad Humphrey, David C. Whitlock, Joe Nasvik Cindy Rusch April Van Etten Wendy Chady Angela Kelty
Concrete Contractor is the Official Media Sponsor of the CFA Foundation Company Certification Program
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LEGAL MATTERS
President Trump’s Early Executive Orders Several of the recent executive orders will impact construction industry contractors.
W
ithin the first week after inauguration, the new president has shown an eager willingness to use executive orders to accomplish change. This is not surprising, as most presidents resort to their executive powers to make minor changes in the way laws are interpreted or enforced. FIRST, President Trump has permitted all federal agency heads to waive requirements of the Affordable Care Act to the maximum extent possible. This step should delay further implementation of ACA requirements, but perhaps more important, it sets the stage for a radical replacement policy. Stay tuned for further details. SECOND, Trump has frozen all regulations that were proposed or pending final approval. All of these regulations must be reviewed by the president or an agency he delegates them to for approval. THIRD, the president has imposed a federal hiring freeze. The intent of this measure is to shrink the federal government. Exceptions to this hiring freeze include the military and critical safety positions. FOURTH, Trump intends to speed approval of the Dakota Access and Keystone Oil pipelines. These executive orders may help concrete contractors who are near the pipeline areas. FIFTH, the new president intends to speed up environmental review for all priority infrastructure projects. This order instructs agencies to set up faster deadlines and environmental approval for high
priority infrastructure projects, giving significant responsibility to a yetto-be-named White House Council on Environmental Quality chairman. This administration’s focus upon infrastructure projects will no doubt help concrete contractors, especially those engaged in maintenance and repair of existing roads, bridges and buildings. SIXTH, the president ordered the Commerce Secretary undertake a 60 day review of regulations affecting American manufacturing. The goal of this order is to speed up permitting and all federal processes for American manufacturers. This could impact concrete contractors as manufacturers will bring projects sooner and with more confidence. SEVENTH, the new president is focused upon illegal immigration. Unfortunately, this could negatively impact concrete contractors by making it harder to find those willing and able to work. By executive order, President Trump will ramp up deportation of those here illegally. This order prioritizes seven groups for deportation including those who have: been convicted of a crime, charged with a crime, committed an offense but not yet been charged, misrepresented themselves to the government, abused a welfare program, been ordered deported, or might pose a risk to public safety or national security. This Executive Order also calls for the hiring of 10,000 additional Immigration and Customs Enforcement agents to work these new deportation cases, but these hires will be subject to congressional appropriations. This
Executive Order also reinstates collaboration between federal and local law enforcement with respect to immigration matters. Finally, this order seeks to block federal grants to so-called sanctuary cities which elect not to enforce immigration. The impact of this order on the construction and concrete industries remains to be seen, but arguably, everyone here illegally has “misrepresented themselves to the government.” From President Trump’s comments it is clear that he intends to focus first upon criminal aliens. It is likely, however, that some good workers will get swept up in the deportation efforts.
NEW I-9 FORM FOR NEW HIRES It is important to note that all employers must be using the new form I-9 for any new hires after January 21. Failure to do so could result in a penalty that ranges from $216 to $2,156. There are several major changes to the form that you should note. Perhaps the most significant change is that the form can now be completed on paper or on a computer utilizing “smart form” technologies. These should make the form easier to complete and there is built-in help. The new form also lets you add additional information and employees can use PO boxes for their address. It is unlikely that the Trump administration will disrupt the implementation and enforcement of the new I-9 form.
6 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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CHALLENGING THE SYSTEM
MOE Specifications on a Project Near YOU!
Ward R. Malisch, PE, PhD, FACI is concrete construction specialist for the American Society of Concrete Contractors. Reach him at wmalisch@ascconline.org. Bruce A. Suprenant, PE, PhD, FACI, is technical director for the American Society of Concrete Contractors. Reach him at bsuprenant@bsuprenant. com.
Seek to understand before committing to modulus of elasticity requirements.
E
ngineers and owners are concerned about deflections of vertical members that control wind movements in tall buildings, and deflections of horizontal members that control floor flatness for final finishes. These deflections are proportional to the size of the members and the stiffness of the concrete. To reduce the deflections and also size of the members, engineers are specifying a minimum concrete modulus of elasticity (MOE) to ensure adequate stiffness of the structure. We have seen modulus of elasticity specifications for tall buildings in Los Angeles, Chicago, Seattle and Toronto. When encountering such specifications, contractors need to ask questions to understand the effects of mix design and testing methods on the measured MOE. Any construction requirements for placing minimum-MOE concrete should be discussed, as well as possible in-place testing and ramifications of a low test if these specifications are not met. For the sample MOE specification shown in the box, the following questions should help contractors have a discussion with the engineer and ready mix supplier.
MOE MIX DESIGN The mix design for a high MOE mix is different than that for a high compressive strength mix. Forget
SAMPLE MOE SPECIFICATION Modulus of Elasticity Construction Requirements: The modulus of elasticity (psi) at 28 days shall be a minimum of 100% of the target modulus of elasticity. Additional modulus of elasticity tests shall be performed on laboratory trial mixtures as follows: a. Concrete for Mild-Reinforced Slabs: The modulus of elasticity at 7 days or at time of formwork stripping, whichever comes first, shall be a minimum of 90% of the target modulus of elasticity. b. Concrete for Post-Tensioned Slabs: The modulus of elasticity at 3 days or at time of tendon stressing, whichever comes first, shall be a minimum of 85% of the target modulus of elasticity. 2. Target modulus of elasticity (psi): a. 57,000 √(f’c), for f’c ≤ 5,000 psi b. 40,000 √(f’c) + 1.0 x 106, for f’c > 5,000 psi c. f’c is the specified concrete strength in psi at 28 days Modulus of Elasticity Tests: ASTM C469/C469M. Modulus of elasticity to be tested using servo-controlled electromechanical or servo-controlled hydraulic testing machines. a. Mild-Reinforced and Post-Tensioned Slabs and Beams: Test two field-cured specimens at 2 days, 4 days, 7 days, 14 days, and 28 days. b. Columns and Shear Walls: Test two field-cured specimens at 7 days, 28 days, 56 days, and 90 days. c. A modulus of elasticity test shall be the average modulus of elasticity from a set of two specimens obtained from same composite sample and tested at age indicated. d. If modulus of elasticity of two specimens varies by more than 15% a spare cylinder shall be tested. The average modulus of elasticity of three specimens shall be considered the modulus of elasticity. e. Modulus of elasticity tests are required for each concrete strength, each concrete mix design and for each aggregate source.
8 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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CHALLENGING THE SYSTEM
Figure 1: Data used in developing the equation relating concrete modulus of elasticity to compressive strength. about what you know about getting a high strength and learn about what it takes to obtain a high MOE value. Ask your ready mix suppliers if they have supplied any projects with minimum MOE specifications. Ask these basic questions: 1. How much did that mix cost? 2. Were local aggregates used or did the aggregates need to be shipped in? How does the mix differ from a high-strength mix? 3. What were the MOE over design values? What is the variability of the MOE at early ages—3 to 7 days? How does that compare to MOE values at later ages—28 to 90 days? Early age MOE values (2 to 7 days) are especially likely to be highly influenced by initial cylinder curing conditions. 4. Did the supplier have any MOE tests fail? If so, what were the consequences? Was in-place testing used? And if so, what in-place tests were used? 5. If the concrete did not meet the specified MOE value at a
required age, how were costs associated with the non-conformance disposition handled?
MOE TESTING Testing for MOE is much different and more sensitive than testing for compressive strength. Observe a MOE test. Ask your local testing labs if They have tested any projects with minimum MOE specifications. Remember that you don’t get to choose the testing lab, so the owner or construction manager may choose one without any MOE testing experience. Ask these basic questions: 1. How much does MOE testing cost? 2. How are laboratory and fieldcured cylinders handled for MOE testing? What effect does cylinder making and curing have on measured MOE values? What special preparation is necessary, such as grinding the cylinder ends? 3. For a given MOE mix testing, what are the average, minimum, and coefficient of variation for MOE
mixes of different values? What is the variability of the MOE at early ages, 3 to 7 days? How does that compare to MOE values at later ages, 28 to 90 days? 4. Did any MOE tests fail to meet the specification requirements? What were the consequences? Was in-place testing used? And if so, what were the in-place tests? 5. Is it possible to reach 90% of MOE at 3 to 7 days to strip formwork for mild-reinforced slabs? Is it possible to reach 85% MOE at 3 days to strip post-tensioned slabs?
MOE INFORMATION NOT PROVIDED Do your homework with the ready mix supplier and test labs. Then have a sit down meeting with the engineer and construction manager. It’s necessary get a feel for what will happen if the MOE values do not meet the specifications. Ask these basic questions: 1. Ask the construction manager how much time has been allotted for stripping forms in the schedule and
10 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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if they are based on concrete mixspecific information on MOE values at early ages? 2. Ask the engineer what in-place tests can be used to verify MOE. Tests on cores? Dynamic MOE (pulse velocity) versus static MOE? Can or should a correlation be done between static and dynamic MOE in the mix design stage? 3. What are acceptable in-place MOE values? 4. Ask the construction manager who pays for in-place MOE testing if the results show that the in-place MOE meets specification requirements? 5. Ask the engineer, what remediation efforts are likely if there are low MOE values for vertical members, horizontal members, or both?
MOE TARGET VALUES The previously mentioned MOE equations used by the specifier can be found in ACI 318 for low-strength concrete and in ACI 363 for highstrength concrete. Figure 1 shows the data used in developing equations for MOE based on compressive strength data. Note that the equations represent an average value with about 50% of the data points above and below that line. However, the specifier has the minimum MOE determined from these equations a minimum value. ACI 318-14 Commentary on the MOE equation for low-strength concrete provides these statements: “Studies leading to the expression for modulus of elasticity of concrete are summarized in Pauw (1960), where Ec is defined as the slope of the line drawn from a stress of zero to a compressive stress of 0.45fc′. The modulus of
elasticity for concrete is sensitive to the modulus of elasticity of aggregate and mixture proportions of the concrete. Measured elastic modulus values can range from 80 to 120 percent of calculated values. ASTM C469 provides a test method for determining the modulus of elasticity for concrete in compression”.
PROTECT YOURSELF! Make sure you do all your homework, and ask questions, and understand the cost and risk before committing to an MOE project. As the Boy Scouts say “Be Prepared!” But we like Yogi Berra’s quote better ”If you don’t know where you’re going, you’ll end up someplace else!” Ed. Note: The ACI documents cited can be purchased at www.concrete.org.
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www.forconstructionpros.com/concrete | January/February 2017 | Concrete Contractor 11
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FLATWORK/SLABS
By Ron Treister
SECONDARY CONTAINMENT Project is Second to None ShotCrete Montana fine-tunes chemical refinery’s totally shot floor.
T
o say the concrete subfloor at the Jupiter Sulfur Refinery in Billings, Mont. was far from being in good condition…would be a gross understatement. It was frankly, in very, very bad shape. Within this industry, there’s no secret that secondary containment on concrete in operational chemical refineries is never less than a difficult challenge for coatings, concrete and steel protection. In this particular application, the challenge was monumental. Just imagine a fertilizer plant where nasty sulfur and ammonia both
are being produced. Add to that, the unforgiving climate of Billings, with its freeze-thaw cycle that only adds to the task of professionally installing any coating system, let alone a premium one offering years of performance with an ironclad warranty. Without question, this was not a project for the weak of heart. But, there was hope. The challenges to be faced were ambitiously confronted by the conscientious, professional team of ShotCrete Montana, along with the assistance of the AC•Tech Oil Buster technical staff. In
Larry Mooney of ShotCrete Montana, worked with “Substrate Sleuth” Johann Bohlmann, AC•Tech’s VP of field operations and a seasoned expert on containment problems, to come up with a well thought-out plan consisting of a composite coating and overall protection system to provide the refinery with a solution that would completely remediate the chemically contaminated substrate. Photo Credit: AC•Tech
12 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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FLATWORK/SLABS The contractor used AC particular, “Substrate Sleuth” Johann Tech's Oil Buster to clean Bohlmann, AC•Tech’s VP of field and coat the contaminated operations and a seasoned expert on concrete slab. containment problems, was called in Photo Credit: AC•Tech to assist and provide cogent recommendations regarding chemical protection and long-term performance for this daunting project. Working in tandem with Larry Mooney of ShotCrete Montana, together they strategized and subsequently, came up with a well thoughtout plan consisting of a composite coating and overall protection system to provide the refinery with a solution that would completely remediate the chemically contaminated substrate. This system would offer both chemical protection at the surface level, and give the customer a more than suitable cosmetic improvement, as well. Overall, this system approach was conceived to give much-needed concrete fortification along with the no-nonsense performance warranty, covering all of the AC•Tech products cementitious layer for leveling to be used. • Applying a primer and then According to Bohlmann, this cominstalling the final topcoat posite application consisted of the guaranteed to withstand years following steps: of chemical abrasion and harsh • Cleaning and coating the conclimatic change taminated concrete slab • Preparing the substrate and the • Rebuilding the damaged concrete steel structural components that and then completely coating it had been affected by chemical with a chemical-resistant system attack. This substrate prep • Including the placement of a program was accomplished with the utilization of sandblasting equipment, assorted hand grinders and other concrete floor preparation tools. • Not surprising at all, one challenging aspect was fighting the weather, which was blistering cold, extremely windy and raining… all of which were impediments to a successful operation Larry Mooney adds,
A cementitious layer for leveling the floor was applied. Photo Credit: AC•Tech
The contractor applied a primer and then installed the final topcoat guaranteed to withstand years of chemical abrasion and harsh climatic change. Photo Credit: AC•Tech
“From the beginning, we knew that the Jupiter Sulfur Refinery had a very damaged concrete floor. Basically, we would be working on a two yearold concrete installation plus its expansion area, as the company was now producing four times its normal capacity! This clearly was not a typical project. In addition to all the challenges we knew we’d be facing, the fact that the refinery could not be shut down while we were working was certainly one to be considered! Luckily, the AC•Tech products used were so easy to apply and cured so quickly, the floor could actually be walked on just four hours after total application!” After the total floor preparation process was completed and the underlayment had cured, the sandblasting process took place, in particular, to open up the surface for better penetration of the AC•Tech 2170 FC Primer. After that had cured, AC•Tech 950 SW was added to the newly primed surface. Bohlmann states, “We mixed the AC•Tech 950 SW with Xylene to achieve the right viscosity prior to application. This is a highly chemical-resistant epoxy topcoat that can perform at optimal levels in any climate…Honolulu or Billings.”
14 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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PRODUCTS
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A compilation of products displayed at the 2017 World of Concrete show. GOMACO Commander III Xtreme Provides Extreme Radii Capability The three-track Commander III Xtreme (Commander IIIx) features the Extreme Package, which includes rotary-sensored slew drives for steering, sensored leg positioning, independent travel circuits to each track, radius software, three-sensor radius system and repeatable mold offset. • Provides the ability to slipform a 24-in. radius • Extreme radius software bundle for the G+ control system allows the operator to program the size of the radius into the controller • G+ manages all aspects of traveling around the radius, including track angles and variable track speeds • Extreme turn capability combined with intelligent All-Track Steering and All-Track Positioning ForConstructionPros.com/12279819
Mortar Net Solutions Introduces DriPlane Drainage Plane for Exterior Rainscreen Systems Mortar Net Solutions introduced DriPlane, its drainage plane for exterior rainscreen systems, at the 2017 World of Concrete trade show. DriPlane is designed for use between the inner structural wall and exterior cladding and is ideal for stucco, thin brick and stone, fiber cement, vinyl and wood siding, manufactured stone and most other absorptive claddings. The easy-toinstall system helps prevent peeling, cracking or blistering by allowing the backside of the exterior finish to drain and dry quickly and completely. Some of the major benefits of DriPlane include: • A 90 percent, open-weave polyester mesh with attached vapor-permeable membrane for rapid drainage and drying. • Molded-in channels providing clear, continuous drainage and ventilation pathways. • Features for standard ¼-inch-thick DriPlane include convenient, 4-foot by 65-foot rolls for rapid coverage and fewer seams, a 10-millimeter thickness option and UV resistance ForConstructionPros.com/12278647
SKILSAW Introduces First Worm Drive Saw Specifically for Concrete The MEDUSAW worm drive saw with integrated wet/dry dust management system is designed to score and cut concrete. • Cut-Ready adjustable plunge lock allows users to quickly and accurately set and make consistent plunge cuts • Integrated rolling foot plate with rubber wheels for movement across hard surfaces • Retractable front pointer accurately guides the saw along the cut line and retracts for tight spaces • Comes with an onboard multi-function wrench to change blades, oil, brushes, water feed attachment and wheels ForConstructionPros.com/12272511
ASV RT-75 Large-frame Compact Track Loader The large-frame, radial-lift RT-75 compact track loader has a 2,650-lb. rated operating capacity and a tipping load of 7,571 lbs. Its Cummins 2.8-liter, turbocharged, Tier 4 Final diesel engine uses a diesel oxidation catalyst that requires no regeneration and no diesel exhaust fluid. It produces 75 hp and 221 ft.-lbs. of torque. The auxiliary hydraulic system produces 35.7-gpm high flow and 3,300 psi. The Posi-Track dual-level suspension includes suspended wheels and axles, fully flexible track and multiple wheel contact points and triple-guide lugs for peak performance on steep slopes. A heavy-duty customization package is available. ForConstructionPros.com/12277953
Putzmeister New Five-Section 47Z Truck-Mounted Concrete Boom Pump The 47Z-Meter concrete boom pump features a new design for its pedestal and five-section boom for increased maneuverability, reduced overall weight and a more user-friendly design. • Boom provides a reach of 134 ft. 10 in. horizontal and 151 ft. 3 in. vertical • Gross vehicle weight reduced to less than 70,000 lbs. • Outrigger leg improvements include four identical screwed-on support cylinders with maintenancefree leg bolts • RS 909 Hopper offers a more robust, yet lightweight, design and an RFID safety switch to prevent operation with the grate open • Ergonic System features wireless computer technology and a Ergonic Graphic Display ForConstructionPros.com/12275398
16 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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*In most areas.
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PRODUCTS Curecrete Distribution Inc. Launches KickStart Concrete Clarity Enhancer KickStart Clarity Enhancer achieves accelerated and enhanced concrete clarity in fewer grinding and polishing steps. • KickStart performs right out of the bucket as a single-component solution (no A or B sides to mix). • The KickStart process requires fewer overall steps. • KickStart can improve the performance, efficiency and longevity of expensive diamond tools • Designed to work in combination with CreteClean Plus with Scar Guard and is only intended for use on floors using the RetroPlate System or Ashford Formula. • Ideal for use on hard steel troweled concrete surfaces and is suitable for new or existing concrete and also concrete restoration projects. ForConstructionPros.com/12288172
Westcoat Introduces New Blonde Acid Stain Westcoat Specialty Coating Systems announces its new Blonde color to its Acid Stain palette. Previously offering 10 colors ranging from greens to browns, the Blonde color adds a lighter neutral tone similar or a wheat or sand hue. Westcoat Acid Stains penetrate and react with concrete and Westcoat’s cement to produce rich, attractive finishes. When applied on concrete, the stain’s metallic ions combine with concrete particles; the resulting oxides produce a variety of mottled colors ideal for both interior and exterior projects. ForConstructionPros.com/12294859
W. R. MEADOWS Introduces PENTREAT W. R. MEADOWS introduces PENTREAT 244-100, a new hydrophobic impregnating sealer used on all types of concrete. • Can be used on horizontal and vertical, new and existing concrete, and masonry above-grade surfaces. It helps prevent chlorideinduced corrosion of rebar, scaling, spalling, freeze-thaw damage and other causes of debilitating concrete. • When applied, this 100% active silane sealer penetrates deeply for maximum protection. ForConstructionPros.com/12293414
Makita’s New XSR01Z is the First Cordless 7-1/4-in. Circular Saw At World of Concrete 2017 Makita announced the new 18V X2 LXT Lithium Ion (36V) Brushless Cordless Rear Handle 7- 1/4-in. Circular Saw, model XSR01Z. It is the world’s first cordless rear-handle 7-1/4-in. circular saw powered by two 18V lithium-ion batteries. The new saw will be available in spring 2017. ForConstructionPros.com/12295652
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18 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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iQ Power Tools introduces the first “Dry-Cut Tile Saw” designed to cut ceramic, porcelain, marble and stone inside or outside with no water and no dust discharge. Additionally, it is lightweight, compact and built on wheels for easy transport to and from jobsites. • 100% compliant with the new OSHA standard on respirable silica dust. • The iQTS244 utilizes a three-stage filtration system which captures up to 99.5% of the dust. ForConstructionPros.com/12292212
Ready to use Blast-Off and the hand Pump Foamer make up a complete maintenance system that safely and effectively removes concrete splatter and buildup from all types of concrete handling and finishing equipment. Formulated with an organic acid derived from sugar cane and beets, Blast-Off deeply penetrates and softens hardened concrete buildup and splatter. Rich, thick foam produced by the Hand Pump Foamer clings to vertical and overhead surfaces. ForConstructionPros.com/12299405
Sakrete Introduces Concrete Countertop Mix at World of Concrete 2017 Sakrete Concrete Countertop Mix can be manipulated to fit any design aesthetic. Using a form, contractors can pour the mix on-site to create the exact shape and thickness desired. • The Concrete Countertop Mix can also be dyed any color to match interior design and décor. • Once poured, the mix takes about 24 hours before you can strip the forms to finish. • It should be properly sealed using a food-safe product after it cures. ForConstructionPros.com/12295565
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The 3001 Concrete Edition three-ton dumper is outfitted with a specially designed concrete chute that will allow delivery and placement of concrete to be faster and more efficient. The metal chute and has been shaped with high side walls to avoid spilling and the narrow shaped front enables precise pouring into the desired location. The 3001 bucket has been designed with special walls that are higher and tapered inward to avoid spilling while transporting concrete. • Larger capacity allows transport of 40 cu. ft. of concrete per load • All-wheel hydrostatic drive allows transportation over rough terrain and in remote areas • Articulated steering allows for a tight turning radius • Bucket swivels to allow material to be unloaded from front or either side ForConstructionPros.com/12296442
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www.forconstructionpros.com/concrete | January/February 2017 | Concrete Contractor 19
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PRODUCTS QUIKRETE FastSet Concrete Crack Repair
Rapid Pavement Surface Repair Materials
Specially formulated as a self-leveling, low-viscosity material, QUIKRETE FastSet Concrete Crack Repair penetrates deep into cracks ranging from hairline to 1-in. before gaining bond strength that delivers permanent repairs. • Rapid-curing, two-part hybrid polyurethane crack repair material that can have traffic on driveways, basements, garages, bridge decks, sidewalks and other horizontal concrete surfaces open in one hour. • The 8.6-ounce cartridges are applied with a standard caulk gun and available for approximately $20 ForConstructionPros.com/12296774
Five Star Rapid Surface Repair products ensure that all traffic can return to full-speed levels in just minutes. Rapid Surface Repair is a range of five unique products offering easy application techniques that result in a durable new surface ready to handle the fastest-moving, heaviest of traffic conditions on any and all roadways. • All Five Star Rapid Surface Repair Products offer fast repair and cure • They bond without primer to concrete, asphalt, steel or wood, thus saving labor time and expense • Additionally, Rapid Surface Repair Products seal and protect, prohibiting further corrosion of reinforcing steel • Extremely safe to use, as they emit no toxic fumes during application ForConstructionPros.com/12296161
Proline's End Grain Edgeliner The “finishing touch” is what the End Grain Edgeliner will add to a wood plank, stamped patio or concrete counter top. Combine Proline’s wood textures with Proline’s End Grain Edgeliner and surprise everyone when they find out it’s concrete. Edgeliners and stepliners should be an essential part of decorative stamping and Proline offers a variety of textures that will work with any stamp you choose! ForConstructionPros.com/12299469
CPS Rover Ride-On Propane Powered Concrete Grinder Concrete Polishing Solutions introduces the CPS Rover, a ride-on, propane powered concrete grinder. The American-made CPS Rover is a zero-turn, propane-fueled grinder with a 32” path. • The precise hand-control and cordless operation makes the CPS Rover the ideal machine for jobs big or small. • An onboard electric head lift makes for easy tooling changes and transport. • An on-board water sprayer allows for easy wet grinding. • Weighs in at 1,115 lbs. with 760 lbs. of grinding pressure and a variable engine speed of up to 3,600 rotations per minute. ForConstructionPros.com/12295797
Fuel-Injected Cobra PROi Breaker Delivers 10% More Power on 10% Less Gasoline The Atlas Copco Cobra PROi is the industry's first gas breaker with electronic fuel injection (EFI) and delivers up to 10% more power than its predecessor the PROe. • Optimal combustion reduces fuel consumption by up to 10% • Custom electronic fuel injection system uses 3 psi - 40 psi less than standard EFI systems • 2-stroke, 90cc engine delivers up to 44 ft.-lb. breaking force • Hand-arm vibration level on 3 axes is below 4 m/s2 to minimize operator fatigue • Weighs just 53 lbs. ForConstructionPros.com/12293615
Chicago Pneumatic Introduces Walk-Behind Trowels Featuring QuickStop
Minnich Manufacturing Dust Collection System
The new walk-behind power trowel line has three main models ideal for most concrete finishing applications. This includes the STG244 (24-in. blade diameter) edger, a standard robust workhorse with the STG375 (37-in. blade) and a high-capacity STG479 (47-in. blade) model for larger areas. • All versions feature QuickStop for safety, foldable low-vibration handles and a maintenance stand • With QuickStop, the blade rotation stops immediately with a zero-degree handle spin. Although blade-rotation is stopped, QuickStop does not shut off the engine when the trigger is released. ForConstructionPros.com/12296312
The Minnich dust collection system meets the requirements for dowel pin drills found in Table 1 of the OSHA final respirable crystalline silica standard. • Weighs just 53 lbs. • The pneumatic dust collector removes dust from the air as the operator drills. • The canister-style unit can be retrofitted to any Minnich on-grade, on-slab, machinemounted or utility drill model. It can also be adapted to fit other dowel pin drill makes and models. • The system comes with drill rod guide collection boots, a 5-gallon pail-type hopper and up to 20 feet of vacuum hose per drill. ForConstructionPros.com/12295735
LAVINA L32G-X and L38GR-X Grinders Superabrasive, the manufacturer of LAVINA, has introduced new propane-powered LAVINA grinders, including a 32-inch, six-head propane grinder L32G-X and a 38-inch remote-controlled L38GR-X. Both models are featuring chain-driven forced planetary drive, powerful Kawasaki FX921V engine, built-in weights and adjustable grinding pressure. ForConstructionPros.com/12299087
20 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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STAND OUT FROM THE CROWD You told us what you wanted -- we listened! NOW TRY the world’s most innovative Mega Screed.
screed COVERAGE 18 ft. boom + 13.5 ft. screedhead = 240 sq. ft. per screed pass
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PRESSURE WASHER Integrated 2500 psi pressure washer & water holding tank
ZERO TURN + 360 o Boom Turret 360O independent control of lower drive frame or upper boom frame
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Ligchine International | www.ligchine.com | (812) 903-4500 | sales@ligchine.com
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PRODUCTS Multiquip Introduces BPX Backpack Concrete Vibrator Motor Weighing only 31 lbs., the BPX is a flexible shaft concrete vibrator ideal for applications such as masonry block fill, footings and slab on grade pours. • The ergonomic frame provides multiple adjustments to reduce operator fatigue and features breathable materials for enhanced comfort • Power is provided by a reliable Honda 2.1 HP gasoline engine that provides easy starting and proven reliability • Throttle control and start/stop functions are located on the shoulder straps for convenience • The BPX is fully interchangeable with Multiquip’s flexible shaft line ForConstructionPros.com/12296300
DOT Concrete Mix DOT Cement is a mobile, onsite volumetric mixer to blend with aggregates and water to produce the large quantities of product needed. Formulated for high sulfate resistance, low shrinkage and long life in freeze-thaw regions ForConstructionPros.com/12295895 •
Aztec Introduces New Green Cleaning Spray Mist System for the LowRider Burnisher Aztec announces the new LowRider Spray Mist burnisher for use on vinyl composite tile (VCT) and polished concrete floors. The LowRider Spray Mist system can be used for spray cleaning with a cleaner/maintainer chemical or for concrete restoration with a concrete restorer solution. • Includes a tray for a one-gallon chemical jug, a brass spray nozzle, PVC tubing, and a 12V pump with 40 PSI • The adjustable spray nozzle position allows for a variable width spray radius, reaching up to a 95-degree angle in front of the LowRider. • The LowRider burnisher, named for its low-profile 3.75” deck height, is available in 21”, 24” and 27” pad widths with additional available upgrades. • Rugged, solid steel body design with an ultra low 3-3/4" profile for buffing and polishing under racks and hard to reach areas. ForConstructionPros.com/12263354
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The Euclid Chemical Company • Cleveland, OH • 800-321-7628
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22 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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FOUNDATION/WALLS
By Joe Nasvik
Building a Concrete
Their home really is their castle.
R
obert Stock and his wife grew up liking castles so when they got married they decided to hold the ceremony in the 700 year old Balgonie Castle located near Fife, Scotland. Afterwards, when they bought property to build a home in Fairfield County, Connecticut, they began to think about owning and living in their own castle. That led them to a meeting with Leigh Overland,
the owner of Leigh Overland Architect LLC located in Danbury, Conn. to begin discussions about designing one and how to build it. “My wife had heard of Insulating Concrete Form (ICF) construction and Overland was familiar with the building system so we considered it along with timber frame, wood “stick build”, and modular construction, eventually deciding on ICF,” he says. The design included a circular three story turret which posed a challenge for ICF but one the sub-contractor, experienced in ICF construction,
was able to achieve. Overland says his challenge was to design a structure that fit with modern suburban life while respecting the client’s castle style aesthetic preference. The design of their home isn’t exactly like the design of the Balgonie Castle aside from some mutual architectural elements and the fact that both castles are built around courtyards. The design of this home includes features from many Scottish castles. Stock says they were also attracted to the energy efficiency that ICF concrete buildings provide.
24 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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This ICF home is their castle, their protector from tornados and wind events. Its energy efficiency provides comfort at a very low price. Perhaps best of all, this concrete house cost about the same as it would if it was wood construction. Photo Credit: Overland Architects
DESIGNING THE BUILDING
PROJECT PARTICIPANTS Architect: Leigh Overland Architect, LLC, Danbury, Connecticut Engineer: B-Cubed Engineering LLC, Westport, Connecticut General Contractor: Tiefenthaler Construction, Norwalk, Connecticut Concrete Contractor: ICF Supply Company, West Hartford, Connecticut. Ready-mix Producer: O + G Industries – Danbury, Connecticut Concrete Pumping Contractor: American Concrete Pumping – Portland, Connecticut ICF Provider: BuildBlock Building Systems, Oklahoma City, Oklahoma.
Though he was aware of ICF construction Overland says this was his first project using it, so his firm had to research and learn how to figure out and detail everything. He liked the idea of the increased amount of insulation in the building and the mass of the concrete, along with the other advantages of building with concrete and ICF. He also realized they would have to involve an engineer familiar with this type of construction. Overland typically specifies all aspects of a construction on his plans and specs, and he thinks this results in better prices, end result and a happy client. Some of the features of the approximately 8,000 square-foot home include: • 11-inch thick walls adding depth and quality to the interior and exterior look • Asymmetrically placed dormers, slate roofs, step-shaped gables • A three story circular turret • Polished concrete radiant floor heating on the first floor (forcedair heating and wood floors on the second level) • Half-round zinc gutters from
All the concrete for the construction was placed by concrete pump. Mixes were designed with strengths of 3,500 psi but were actually approximately 4,000 psi in place. Photo Credit: Jim Ryan
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FOUNDATION/WALLS A view from inside the turret. 1,000 ICF’s were cut to the proper angle and urethane foam was applied to the joints to keep concrete from leaking out during placement as well as hold the blocks in position. Photo Credit: Jim Ryan
Germany • Euro-style chimney pots on top of chimneys • No trim around windows and doors • A Dryvit exterior finish placed directly over the exterior ICF block insulation with a simulated limestone finish. • A significant undeveloped space for future development Overland used a generic ICF specification so that different ICF manufacturers could supply prices. His office also supplied general contractor bidders with the names of sub-contractors who were familiar with installing ICF products. BuildBlock Building Systems with headquarters in Oklahoma City, Okla. was the ICF product they decided to use.
BUILDING THE STRUCTURE The owner and architect selected Tiefenthaler Construction, Norwalk, Conn., as their builder. Ross Tiefenthaler says his company is 40 years old but had little experience with ICF construction previous to this time so the selection of the concrete contractor was helpful to all the trades due to their ICF experience. The contractor was the ICF Supply Company located in West Hartford, Conn., both a supplier of BuildBlock products and
an experienced installer. The owner, Jim Ryan, says he has been an ICF distributor and installer for over 16 years. His company also provides training and technical support to crews in the field. Construction started in late November of 2013 and went through an especially cold, severe winter. Ryan and his crew placed concrete in the ICF forms at temperatures as low as 10 degrees without worrying about the concrete freezing—an
The finished turret after the Dryvit finish was completed. Photo Credit: Jim Ryan
26 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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FOUNDATION/WALLS ICF’s are manufactured in a number advantage that ICF’s have. of ways. The ones used for this “On one bad-weather day construction are interlocking blocks with our Ready-mix Producer plastic spacers that double as supports batched only seven loads to hold rebar reinforcement in place. of concrete and our job Photo Credit: BuildBlock received one of them,” says Tiefenthaler. He says it’s easier to build ICF walls in the winter placement. Plumb is typithan with standard wood-frame concally rechecked after placement and struction methods. adjusted if necessary. The 3,500 psi After completing a multi-elevation concrete was pumped into all the footing for the house Ryan and his entire first floor walls at one time. crew assembled the four-foot long, The 12 foot diameter turret was 16-inch tall, 11-inch wide blocks for the most challenging and intricate all the walls on the first floor level of part of the ICF work. Ryan said they the house. The blocks interlock and used over 1,000 pre-cut, pie-shaped workers placed #4 rebar horizonpieces for the turret. Because it starts tally in each course of blocks, vertical approximately eight-feet above rebar being placed after the blocks ground the engineering was more were all in place for wall. Next, stagcomplicated too. ing was assembled on the inside of The first floor of the house is conthe walls so that workers could pump crete and has floor radiant heating concrete into the walls from the top. and the second floor is wood with But the staging also braces the walls forced air heating. to keep them plumb during concrete All the exterior walls and the
load-bearing walls inside the home are concrete but the rest of the inside walls are wood frame, making future remodeling easier to accomplish.
WORKING WITH OTHER TRADES Tiefenthaler says he was grateful for Ryan’s expertise and his willingness to consult with the other trades, as they weren’t familiar with this type of construction. Plumbing and electrical were tunneled into the expanded foam on the inside of the walls. At first they tried to form channels in the foam with an electric heat melting tool but it proved too slow so they used an electric chain saw mounted on a guide-bar to speed up the process.
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The Stocks have lived in their new home for two years now. They knew some of advantages of living in a concrete house such as energy efficiency but decided to have a Home Energy Rating System (HERS) test performed to determine what the energy efficiency of their home really was. The U.S. Department of Energy states that an average home for resale has a score of 130 on the HERS Index while an average new home has a rating of 100. Stock says their HERS score was 46, meaning that his house is 65 percent more efficient than the average house for resale. He adds that the floor radiant heating system supplies most of the heat for their home (upstairs and downstairs) and so much heat is retained that it can be difficult to cool it down in the evening, in the winter when the HVAC system is off, especially if the oven has been running, adding that they frequently have to open their kitchen windows for a little bit to cool the room down—the second floor forced-air system doesn’t run much at all.
28 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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Ryan built the ICF walls for the home during a particularly severe Connecticut winter. He wasn’t worried about his concrete freezing in the ICF forms but just to be sure a testing lab company was hired to perform 30-day tests with a Windsor Probe Test on the concrete and learned that his specified 3,500 psi mix averaged nearly 4000 psi in 28 days. This supports his belief that building with ICF can be safe during the winter months. In the past there’s been a significant difference in cost between building homes with structural concrete versus standard wood frame construction methods but the cost difference between the two systems is similar now. ICF walls provide the structural wall, insulation, and include the expanded foam surface for exterior finishes like stucco or Dryvit, making them less costly to install. Overland says the two systems are nearly equal in cost but far from
equal in performance and quality. Also, he says building codes have changed in his area, requiring continuous insulation for commercial buildings and he thinks this will become the standard for residential home construction as well. Overland recommends ICF construction to all his clients now and says there is increasing demand. In addition to energy efficiency he says clients like the fire and storm
resistant security of living in concrete homes. “Wellness certifications” are also beginning to be required by his clients, especially younger people and that’s easier to obtain with ICF construction too. Workers stand on scaffolds to place the concrete but the scaffolding also holds the formwork in a plumb position until the concrete is hard. Photo Credit: Jim Ryan
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DECORATIVE CONCRETE SPOTLIGHT ON DECORATIVE CONCRETE
By Greg Udelhofen
MAGNETIC TECHNO Delivers Consistent Quality Stamped Concrete Design 30 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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Finished flagstone design illustrates quality achieved using the magnetic seamless pattern stamps. Photo Credit: Deco-Crete Supply
Proline Concrete Tools’ Seamless Pattern Stamps provide decorative concrete contractors with an accurate and efficient way to produce a variety of stone-looking designs in the same time it takes to produce a seamless texture design.
W
NOLOGY
y
hat if you could offer and deliver a pattern design replicating Ashlar or flag stone without having to tool out the noticeable raised grout joints that form when two mats are butted together? That type of technology would obviously save on the labor required to correct the look of those noticeable butt joints and it certainly would enhance the overall look of the finished project. Proline first demonstrated its new Seamless Pattern Stamps (SPS) at the World of Concrete 2016, and has since been perfecting the product, building manufacturing equipment to mass produce the product, and working with distributors to educate contractors on the application of the product. “Our seamless texture skins have been a popular product because there’s no grout pattern to match and it allows contractors to create a random seamless texture design by simply rotating the stamp when you move it,” notes Tyler Irwin, Proline sales manager. “We wanted to provide the same type of capability for pattern designs, allowing contractors to deliver a seamless stamped pattern option as easily and as quickly as they can with a seamless texture design.”
For the past year Proline has been tweaking the SPS product to make them lighter and more durable, as well as building the production equipment required to mass produce the four-by-four foot stamps. “We’ve built our business on being able to deliver a quality product in a timely fashion,” Irwin says. “If a customer orders a basic set of stamps today, we’ll ship them out the next day.” Fifteen to 20 years ago, a basic set of decorative stamps consisted of six two-by-two foot stamps. Over the past 10 years, stamps have increased to larger sizes, allowing contractors to complete projects faster. Today, stamps are now available in fourby-four foot dimensions that again increase a contractor’s productivity. Larger stamps weigh more, which is why Proline has been working with high-quality urethanes to reduce the weight, while maintaining the durability of the new SPS product line. “We’ve basically spent the past year working out our entire manufacturing system in order to deliver the right product,” Irwin notes
MAKING THE RIGHT PRODUCT WORK RIGHT It’s easy to understand why the development of the new SPS product has taken as long as it has; it’s all about delivering a consistent quality job each and every time the stamps are used. The stamps are designed to be overlapped six to 12 inches to create a seamless pattern. The embedded magnets in the overlapped stamps register and lock in place. Even when the stamps are rotated a quarter turn to create a random pattern, the magnets register to maintain a seamless design. “Whether it’s the seamless texture designs that have no grout lines, or the seamless pattern design with grout lines, you cannot tell where the two stamps meet,” Irwin says. “With conventional pattern stamps, even with the best work of tooling out the excess concrete that squeezes out between stamps when butted
www.forconstructionpros.com/concrete | January/February 2017 | Concrete Contractor 31
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DECORATIVE CONCRETE together, it’s still noticeable where the stamps meet. “We always strive to develop products that will emulate natural stone and the SPS technology advances the look and feel of the final project,” Irwin adds. “And the ability to create random stone patterns by simply rotating a stamp a quarter turn adds to the unique and authentic design that can be created.” Standard pattern stamps typically offer four to five stone pattern options. Proline’s SPS magnetic technology creates the possibility of 30 different stone designs simply by rotating the stamps to create all the various designs. Using a different pattern design of the same stone can double the options of how the final project looks.
Jason Geiser aligns mats to achieve a continuous seamless pattern. Photo Credit: Deco-Crete Supply
Embedded magnets register the pattern when overlapping mats. Photo Credit: Deco-Crete Supply
For commercial and residential decorative concrete contractors, the SPS technology could very well make their old stamps obsolete by delivering a higher quality project and much higher profit margin simply be reducing the labor required to correct grout joints. It allows contractors to produce a high-quality stone design in same time it takes to produce a seamless texture design.
FIELD TESTED Proline knows its products are only as good as the market says. Enter Jason Geiser, owner of DecoCrete Supply, an Ohio decorative
concrete products distributor who provides demonstrations and training on the industry’s latest offerings. Geiser started working as a decorative contractor in 2000. He transitioned to distributor in 2007, using his contractor experience to field test and demonstrate new products at his Orrville, Columbus and Cleveland locations. “I’ve poured over a half million yards of decorative concrete and 75 percent of my employees have field experience,” Geiser states. “My front parking lot is our testing grounds. We’re always testing and demonstrating new products and techniques.” For Geiser, the time saved and the improved quality produced are the two primary benefits of the SPS product line. “With the overlapped grout lines locking into place, that alone is going to save so much time on a project by eliminating cleanup of a grout joint,” he states. “And, I’ve been in this business long enough to where I can pick out a pattern just by looking at a finished project. I can’t when the seamless pattern stamps are used.” Time saved and improved quality achieved with the four-by-four foot stamps enables contractors to complete more work in a given day.
Jason Geiser, owner of Deco-Crete Supply, uses a tamper to set the stamp design. Photo Credit: Deco-Crete Supply
32 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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Geiser removes a stamp to reveal the seamless pattern design created on a new slab. Photo Credit: Deco-Crete Supply
“If you’re using standard smaller stamps, you really have to plan out your pour, and you’ll probably have to break up a project into several pours,” Geiser says. “With the larger stamps and the seamless pattern capability, you can keep moving at a much faster pace without worrying about cleaning up joints. “We have contractors who have
rented the stamps we have for testing and demonstrating, and a lot those guys are ready to go when the final refined stamps are introduced to the market,” Geiser says. “We have contractors and their customers who like seamless texture finishes and we have contractors and their customers who prefer a stone pattern, like flagstone. This product will help
Stamped slab ready for final finish without additional tooling. Photo Credit: Deco-Crete Supply
contractors meet the decorative concrete industry’s stone pattern demand in a cost-effective way that’s good for contractors and their customers.”
www.forconstructionpros.com/concrete | January/February 2017 | Concrete Contractor 33
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SPECIFICATION GUIDE: GRINDERS
Grinders
A compilation of technical information when choosing your next grinder.
1 Concrete Polishing Solutions G-320D and G-320D PRO Grinders With more than seven years in production, the G-320D and G-320D PRO set the standard in polished concrete equipment. With powerful motors, upgraded slip-clutches, and flex head technology, these machines not only have more than enough torque to grind through heavy mastics and coatings, but also make excellent polishing machines. ForConstructionPros.com/12152035 Model
Dimensions (LxWxH)
Weight (lbs)
Horsepower
Amperage
Grinding Path (in.)
Grinding Pressure
Planetary/ Non-Planetary
Water Tank (Yes/No)
G-320
49” x 33” x 43”
980 lbs.
20 hp
30 amp
32”
600 to 750 lbs.
Planetary
Yes
Model
Dimensions (LxWxH)
Weight (lbs)
Horsepower
Amperage
Grinding Path (in.)
Grinding Pressure
Planetary/ Non-Planetary
Water Tank (Yes/No)
G-320D PRO
53” x 33” x 61”
882 lbs.
31 hp
N/A (Propane powered)
32”
500 to 650 lbs.
Planetary
Yes
2 EDCO Magna-Trap, Heavy-duty Floor Grinder/Polisher EDCO introduces Magna-Trap Systems, opening a new era in concrete grinding surface preparation equipment and tooling specifically designed for the rental industry. With both rental and retail opportunities, EDCO’s Magna-Trap System solves virtually every concrete grinder surface preparation application. The combined capabilities of the 4 core Magna-Trap tools, (Dyma-Dots, Dyma-Segs, Dyma-PCD w/ Backing Segment, Strip-Serts) are designed to solve most surface preparation applications. These options are available in the new Magna-Trap Rental Packages. ForConstructionPros.com/12140683 Model
Dimensions (LxWxH)
Weight (lbs)
Horsepower
Amperage
Grinding Path (in.)
Grinding Pressure
Planetary/ Non-Planetary
Water Tank (Yes/No)
EDCO Magna-Trap
48” x 26” x 40”
330 lbs.
5 hp (electric) / 18 hp (propane)
23 amps
22”
55 lbs. per tool
Non-Planetary
No, water hose hookup
3 LAVINA X Series
The X series includes a full range of models, from 7- and 13-inch edgers to a 32-inch self-propelled model and a 38-inch remote-controlled propane model. Lavina machines are powerful, durable, versatile and very easy to use, but with efficiency as the top priority. The most notable feature of the X line is the minimized machine maintenance ForConstructionPros.com/12023743 Model
Dimensions (LxWxH)
Weight (lbs)
Horsepower
Amperage
Grinding Path (in.)
Grinding Pressure
Planetary/ Non-Planetary
Water Tank (Yes/No)
LAVINA 30G-X
76” x 32” x 47”
610 lbs.
18 hp
N/A (Propane)
30”
375 lbs.
Forced Planetary
Yes
Model
Dimensions (LxWxH)
Weight (lbs)
Horsepower
Amperage
Grinding Path (in.)
Grinding Pressure
Planetary/ Non-Planetary
Water Tank (Yes/No)
LAVINA 32M-X
96” x 34” x 51”
25 hp
35 amps, 3 phase, 380-460V, 500/60 Hz
32”
715 lbs.
Forced Planetary
Yes
1,245 lbs.
36 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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Bringing in generators or hiring electricians to wire up your 3-phase grinders is both time-consuming and expensive. You can save a bundle on your bottom line and boost your productivity with two great 230V, single-phase grinders from Scanmaskin. The Scan Combiflex 650 features a 26-inch grinding path, so it can easily handle large commercial jobs, while the 330 is your go-to unit for edge grinding. The shroud rotates in seconds, so you can switch easily between left- or right-side edgework.
SCAN COMBIFLEX 330 « Perfect for edge grinding right up next to a vertical surface « 13-inch grinding path « Productivity rates of 270–430 square feet per hour « 230V, single-phase « 250–750 RPM « Direct gear reduction system; holds 9 tools
SCANMASKIN ADVANTAGES « Superior engineering directs the torque of the machine at the floor—not at your hip
« Weighs 143 lbs
SCAN COMBIFLEX 650
« Durable, all-steel construction—right down to the dust shroud
« Ideal for grinding on big jobs with large open areas
« Belts rated for up to 5,000 hours
« Productivity rates of 645–970 square feet per hour
« Low-maintenance design
« 230V, single-phase
« Low-vibration design
« 350–900 RPM
« 26-inch grinding path
« 3-head planetary drive system; holds 18 tools « Weighs 705 lbs
Scanmaskin machines are built to WORK, not to be worked on. Find out what else sets Scanmaskin machines apart at www.jondon.com/scanmaskin.
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SPECIFICATION GUIDE: GRINDERS
4 The Prep/Master Jr. grinder by STI
8
The Prep/Master Jr. grinder by STI works extremely well in small, hard-to-reach areas that requires a more compact design — perfect for residential garage floors. This grinder is very aggressive, yet extremely easy to operate due to the smooth operation of the STI rotary gear system. In addition, the low price of the Prep/Master Jr. is very affordable and fits any project budget. ForConstructionPros.com/12298967
5
Model
Dimensions (LxWxH)
Weight (lbs)
Horsepower
Amperage
Grinding Path (in.)
Grinding Pressure
Planetary/ Non-Planetary
Water Tank (Yes/No)
Prep/ Master Jr.
50” x 23” x 48”
450 lbs.
7.5 hp
40 amp
23”
265 lbs. (with pocket weights)
Non-Planetary
Yes
SASE PDG 5000P - 20” Planetary Floor Grinder The PDG 9000P features a 20” grinding width. According to the company, this machine is pefectly balanced and is built for low maintenance. It includes a powerful Gx390 Honda Engine and connects to the SASE BULL dust extractors for dust-free operation. Other features include: • Operator Friendly Control Panel • Standard feature - flexible grinding heads • Includes both metal bond QCS and resin bond flex plates ForConstructionPros.com/12299009 Model
PDG 9000P
Dimensions (LxWxH)
Weight (lbs)
Horsepower
Amperage
Grinding Path (in.)
Grinding Pressure
Planetary/ Non-Planetary
Water Tank (Yes/No)
N/A
430 lbs. (without propane tank)
N/A
N/A
20”
220 lbs.
Planetary
N/A
6 MK Diamond MK-SDG and MK-DDG Double Disc Grinder
The MK-SDG has a fully encapsulated grinding shroud with vacuum pick up. It features a tapered front nose that provides enhanced visibility. The removable handles and nose weight provide for easy transportation and storage. An easy to operate foot pedal raises grinding discs off the ground for engine starting and idling. The SDG-11 is powered by a gas Honda GXV340 engine. The MK-DDG (pictured) uses a 10 or 20 segment, 10” diameter diamond grinding head. ForConstructionPros.com/10082101 Model
Dimensions
Weight
Horsepower
Amperage
Grinding Path
Grinding Pressure
Planetary/ Non-Planetary
Water Tank Yes/No
MK-DDG Double Disc Grinder
50” x 25” x 40”
234 lbs.
8.9 hp
N/A
20”
160 lbs.
Non-Planetary
No
7 Husqvarna PG 820 RC with Dual Drive Technology
Husqvarna Construction Products releases a new, self-driven remote controlled version of Husqvarna PG 820 with patented Dual Drive Technology. The PG 820 RC enables significantly higher productivity and even better work results together with more ergonomic operation and transport. While running, the operator has time to prepare the next set of tools, adjust hoses, etc., which means better use of labor time. ForConstructionPros.com/12028632 Model
Dimensions
Weight
Horsepower
Amperage
Grinding Path
Grinding Pressure
Planetary/ Non-Planetary
Water Tank Yes/No
Husqvarna PG 820 RC
Not available at press time
Not available at press time
17 hp
32 amps
32”
737 lbs.
Planetary
Not available at press time
38 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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8 Kut-Rite Conquer30
For contractors looking at those hard-to-get-to places, Kut-Rite offers the 598-pound Conquer30, a grinding and polishing machine that combines a 10 hp motor with a 30-inch grinding/polishing path – and, most importantly, a low-profile edge. Because the Conquer30 reduces the height of the machine’s bowl more than any other unit in the Conquer series, it is also most adept at closer edging. ForConstructionPros.com/10705570 Model
Dimensions
Weight
Horsepower
Amperage
Grinding Path
Grinding Pressure
Planetary/ Non-Planetary
Water Tank Yes/No
Kut-Rite Conquer30
70” x 30.75” x 44”
598 lbs.
10 hp
25 amps
30 in.
N/A
Planetary
Yes
9 General Equipment SG12/E
Designed for smaller-scale surface preparation projects, General Equipment Co.’s SG12/E single-head surface grinder offers high performance, durability and ease-of-use, making it ideal for anyone from professional contractors to do-it-yourself homeowners. Powered by a totally enclosed, fan-cooled 1.5-horsepower electric motor, the SG12/E features a single rotating disc with a 12-inch-wide working width. Applications for the SG12/E include grinding concrete surfaces, removing mastics, adhesives, epoxies and urethanes, breaking up deposits of grease and dirt, removing rubber carpet backing and industrial residues, and polishing more delicate terrazzo and marble floor surfaces. ForConstructionPros.com/12105500 Model
Dimensions (LxWxH)
Weight (lbs)
Horsepower
Amperage
Grinding Path (in.)
Grinding Pressure
Planetary/ Non-Planetary
Water Tank (Yes/No)
SG12/E
39” x 19.75” x 40.50”
242 lbs.
1.5 hp
15 amp, 115 VAC, single phase
12”
N/A
Non-Planetary
No
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SPECIFICATION GUIDE: GRINDERS
10 HTC 270 EG - Stand Up Edge Grinder
The HTC 270 EG is pioneering a stand-up edge grinding and polishing machine. It has a maximum head height of only 4.5 inches to fit under shelves. The HTC 270 EG comes standard with variable speed for complete control and a rotating, floating shroud with adjustable wheels to grind and polish up to the wall or slightly away. ForConstructionPros.com/10247544
Model
Dimensions
Weight
Horsepower
Amperage
Grinding Path
Grinding Pressure
Planetary/ Non-Planetary
Water Tank Yes/No
HTC 270 EG
41” x 20” x 33”
90 lbs.
3 hp
30 amps
10.6 in.
90 lbs.
NonPlanetary
No
Model
Dimensions
Weight
Horsepower
Amperage
Grinding Path
Grinding Pressure
Planetary/ Non-Planetary
Water Tank Yes/No
HTC 800 RX
87” x 33” x 48”
1,200 lbs.
20 hp
40 amps
32”
530-726 lbs.
Planetary
Yes
Model
Dimensions
Weight
Horsepower
Amperage
Grinding Path
Grinding Pressure
Planetary/ Non-Planetary
Water Tank Yes/No
HTC 950 RX
53” x 38” x 50”
1,323 lbs.
20 hp
40 amps
36”
617-882 lbs.
Planetary
Yes
11 Rotator Solutions, a div. of Dickson Ind. - DG-10-115 The DG-10-115 concrete grinder/polisher is built for constant commercial and rental markets. Narrow enough to fit through a standard 36” door, the DG-10-115 is ideal for grinding/polishing residential kitchens, bathrooms, and utility rooms. The machine uses115 VAC or 230 VAC single phase and features fully adjustable handle bars which fold down for easy loading in pickups, SUV, and even station wagons. ForConstructionPros.com/12028649
Model
Dimensions
Weight
Horsepower
Amperage
Grinding Path
Grinding Pressure
Planetary/ Non-Planetary
Water Tank Yes/No
DG-10-115
36” x 24” x 37”
225 lbs.
1-1/2 hp standard; 2 hp optional
15 amps; 20 amps
10 in.
Full weight of machine
Non-Planetary
No
Model
Dimensions
Weight
Horsepower
Amperage
Grinding Path
Grinding Pressure
Planetary/ Non-Planetary
Water Tank Yes/No
DG-10-10-115
36” x 24” x 37”
350 lbs.
Dual 2 hp; 230 volt
15 amps
20 in.
Full weight of machine
Non-Planetary
No
Model
Dimensions
Weight
Horsepower
Amperage
Grinding Path
Grinding Pressure
Planetary/ Non-Planetary
Water Tank Yes/No
Worx
100” x 64” x 76”
3,500 lbs.
40, 60 or 80 hp
N/A
Up to 16 in.
N/A
No
No
40 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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SPECIFICATION GUIDE: GRINDERS
12
The Aztec UltraGrind The award winning UltraGrind is Aztec’s propane-powered, planetary head, gear driven, concrete grinding and polishing machine. The UltraGrind is designed for the more aggressive concrete floor grinding and polishing applications, where the goal is to both remove material and highly polish concrete floors. • Industry-standard 2-inch exhaust ports for concrete dust vacuums • Powered by the new 20 hp Kawasaki 603cc engine, featuring a heavy duty canister air filter • CE, EPA/CARB, LEED and GS-42 certified. ForConstructionPros.com/12299019
13
Model
Dimensions (LxWxH)
Weight (lbs)
Horsepower
Amperage
Grinding Path (in.)
Grinding Pressure
Planetary/ Non-Planetary
Water Tank (Yes/No)
UltraGrind
79” x 32” x 46”
930 lbs. with water tank
18 hp
N/A
30”
Up to 780 lbs.
Planetary
Yes
Model
Dimensions (LxWxH)
Weight (lbs)
Horsepower
Amperage
Grinding Path (in.)
Grinding Pressure
Planetary/ Non-Planetary
Water Tank (Yes/No)
The Refresher
43.25” x 32” x 42.25”
482 lbs.
18 hp
N/A
30”
330 lbs.
Planetary
Yes
Model
Dimensions (LxWxH)
Weight (lbs)
Horsepower
Amperage
Grinding Path (in.)
Grinding Pressure
Planetary/ Non-Planetary
Water Tank (Yes/No)
UltraEdge
50” x 32” x 42”
478 lbs.
18 hp
N/A
13”
75-175 lbs.
Planetary
No
Terrco Model 3100LP-K The Terrco Model 3100LP-K features a 40 hp Kubota LP gas four head (12 stones) floor grinder. ForConstructionPros.com/12028642 World of Concrete 2015 Booth #O30424
Model
Dimensions
Weight
Horsepower
Amperage
Grinding Path
Grinding Pressure
Planetary/ Non-Planetary
Water Tank Yes/No
Terrco Model 3100LP-K
72.25” x 29.5” x 74”
1,590 lbs.
40 hp
N/A
28”
1,220 lbs.
Non-Planetary
Yes
Model
Dimensions
Weight
Horsepower
Amperage
Grinding Path
Grinding Pressure
Planetary/ Non-Planetary
Water Tank Yes/No
Terrco Model 6200
80” x 55” x 54”
2,300 lbs.
40 hp
46 amps / 460 V
53.5 in.
1,885 lbs.
Non-Planetary
Yes
Model
Terrco Model 3100-3P-SPV
Dimensions
Weight
72.25” x 29.5” x 52” 1,425 lbs.
Horsepower
Amperage
Grinding Path
Grinding Pressure
Planetary/ Non-Planetary
Water Tank Yes/No
25 hp
60 amps/230V or 30 amps at 460V
28”
1,090 lbs.
Non-Planetary
Yes
42 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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Dust Extraction Systems For All Industries We are Here to Help Pullman Ermator and its team of experts from numerous industries are here to help. With its iComply program we can help the contractor through our distribution chain with OSHA compliance.
What is Silica? • Silica is quartz, and is found naturally in almost all rock, sand, soil, brick and concrete products
“The tools that we need to protect workers are already out there. They’re available. They’re not prohibitively expensive, and they need to be implemented.”
• Respirable crystalline silica particles penetrate deep into the lungs causing lung disease • Silica exposure remains a serious threat to nearly 2 million U.S. working, including more than 100,000 workers in high risk jobs such as abrasive blasting, foundry work, stone-cutting, rock drilling, quarry work and tunneling
-Deven Johnson
Director of Training, Health and Safety for the Operative Plasterers’ and Cement Masons’ International Association
Silica Health Hazards Symptoms Shortness of breath Loss of appetite Chest pains
Fatigue Severe Cough Cyanosis (bluish skin)
Silicosis
COPD
A non-reversible lung disease with diffuse nodular pulmonary fibrosis Acute Silicosis Chronic Silicosis Accelerated Silicosis
(Chronic obstructive pulmonary disease)
A lung disease that causes obstructed airflow from the lungs by becoming thick and inflamed while air sacs lose their elastic quality. Too much mucus is made and blocks airways
UPDATED FINES FOR 2017 Type of Violation
Current Maximum Penalty
NEW Maximum Penalty
Serious
$7,000 per violation
$12,471 per violation
Failure to Abate
$7,000 per day
$12,471 per day
Willful or Repeated
$70,000 per violation
$126,000 per violation
How do I Comply? • Exposure determination • Use Table 1 or Monitor exposure • Create a written exposure plan • Designate a competent person
• Provide medical surveillance • Provide proper training • Required recordkeeping • Use proper HEPA dust collection
Go to www.iComplysilica.com
To see a list of presentations to find one near you
How to Choose a HEPA Vacuum Important points of requirements • High quality HEPA filters that are tested and certified, with a rating of at least 99.99 at 0.3 micron • 25 CFM PER BLADE INCHES REQUIRED FOR HAND GRINDERS • High CFM & Water Lift for proper matching to equipment • Must have a mechanical filter cleaning method, contained allowing no dust to escape • Multi levels of filtration, that include a cyclonic chamber, prefilters, HEPA’s and pre-separators • Drop down bagging containment systems, no dust can or tray • Availability to attach tools for collection at the source • Wet and dry availability when needed
CONTACT US AT CONC0117_36-43_SpecGuide.indd 43
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PRODUCT FOCUS
By Matt Van
Diamonds Are a Concrete Contractor’s Best Friend
Proper blade selection makes for a happy working relationship.
W
hen it comes to cutting concrete, not all blades are created equal. Blades vary in the number of diamonds, size, shape, cost and performance, but it’s the application that’s the true differentiator. The questions can be numerous: Which blade will work best on what kind of concrete? How large should the blade be? Will the same blade used on a basement floor work well to cut two inches into a driveway? Are there new technologies I should know about and how do I keep up? Basically, the answers fall into these categories: the hardness and abrasiveness of the material to be cut; speed, efficiency, longevity, size and affordability of the blade needed; and the quality of cut desired. Understanding the science behind the making of diamond blades, how they work and the kinds of blades available will help you choose an option with the right characteristics for your application.
THE SCIENCE OF BLADE MAKING AND HOW BLADES WORK Concrete cutting blades are made with four basic components: • The metal core: a precision-engineered steel disk with a rim that holds the diamonds • Synthetic diamonds: the sharp cutting teeth that slice through the concrete • The matrix: a metal bond that holds the diamonds in place until they wear away with use • The weld: attaches the cutting segments (matrix and diamonds) to the core It’s the exposed diamonds on the surface of the blade’s perimeter and in the radius that do the cutting, using a high-speed abrasive action. As the blade cuts, the matrix begins to wear away, releasing the worn diamonds and exposing new ones embedded within the matrix, which continue the cutting. Larger diamonds favor speed and smaller fine diamonds favor longer blade life. The efficiency of the blade depends on the hardness of both the matrix and the concrete, and the number of diamonds embedded into the radius. The relationships work this way: When cutting soft
concrete, a hard metal bond is needed so the diamonds can be fully used before being shed. When cutting hard concrete, which will wear down the diamonds more quickly, the bond should be soft to enable easier erosion of the matrix ensuring exposure of new diamonds. Blade making is a science. There are a handful of companies that manufacture quality diamond blades. Part of the research process is experimentation with mixtures of diamonds and binder in a variety of concrete and masonry types. Bosch, a leader in diamond blade development for concrete and masonry applications, works with concrete and masonry contractors in the field to develop new diamond formulations. Through extensive testing, these chemical formulations and design changes have improved durability.
TYPES OF BLADES Concrete cutting blades come in three variations: segmented, continuous and turbo. In addition, there are a variety of options for size and shape within these categories. Segmented Blades, the most common option, are used for fast cutting in concrete. With segments of varying sizes around the perimeter, the gullets
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LEAN, MEAN, CUTTING MACHINE Husqvarna Construction Products’ updated K 970 power cutter and brand new Vanguard HS diamond blade make an efficient team to help you cut through your jobs quickly - every time. The K 970 features our new semi-automatic belt-tensioning system, SmartTension. This system makes it easy to tension the belt at the optimum level for the machine. When paired with one of three Vanguard HS blade specifications, you can cut almost anything. The Vanguard HS features segment-wear indicators, depth control cooling holes and .500" high segments that reduce side friction and promote cutting speed. To learn more about this powerul duo or to located your nearest dealer, please visit our website www.husqvarnacp.com or call your Husqvarna representative. facebook.com/husqvarnaconstruction
youtube.com/husqvarnaCP
HusqvarnaCP_Americas
Copyright Š 2017 Husqvarna AB (publ.). All rights reserved. Husqvarna is a registered trademark of Husqvarna AB (publ.).
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PRODUCT FOCUS (gaps) between the segments disperse the dust, allowing the user to efficiently cut the concrete. The gullets also help to keep the blade cool. These blades are best for high production jobs where speed is paramount. Continuous Rim Blades provide fast and clean cutting with minimum chipping at a reasonable cost and can be used on small- and large-diameter angle grinders. These blades cut more slowly and are used when precision is needed. Turbo Blades combine the advantage of both continuous rim and segmented blades and can be used wet or dry. This type of blade can simulate the precision of continuous rim blades. They provide a good-quality cut at high speed and are used in many applications, such as cutting for repair work.
CRITERIA FOR SELECTING THE RIGHT BLADE: LONGEVITY VS. COST
Manufacturers offer diamond blades in a variety of quality and cost levels ranging from basic economy to premium. One difference is in the diamond content. Upgrading may raise the cost 20 percent or more, but there will be significantly longer blade life. For small cutting jobs where the blade isn’t used to full capacity there’s more opportunity to use an economy blade. But frequent-use users actually save money on a cost-per-cut basis with a premium blade. When cutting concrete it’s all about maximizing the cost of cut per inch or per foot. A little math can help you calculate the ROI on the blade. Just calculate the cost of the blade divided by the (length times width) of the cuts made. Cutting hard concrete can shorten blade life and can reduce cutting speed. For a heavy job with an economy blade, a tradesman may have to change the blade daily. A premium
blade could conceivably go a week on the same job. And fewer blade changes means a faster job, greater efficiency and better profit margin.
CONCRETE COMPOSITION (AGGREGATE) The content of concrete can be crushed (limestone, granite, sandstone) or uncrushed; fine (passes through a #4 sieve, .187" square opening) or coarse (what’s left). The amount of sand in the aggregate also affects the hardness and abrasiveness of the concrete. Aggregates are geographically similar, with some variation. Florida has softer concrete while St. Louis’ is flint-based river gravel. Find an aggregate map of the United States to use as a general guide and select blades accordingly. Large and/or hard aggregates tend to cause blades to cut more slowly and are harder to cut, requiring a softer bond; small and/or
Dynamic Systems Approach to Waterproofing and Restoration Miracote - Cementitious Renewal Systems & Protective Coatings MiraFlex - Vapor Permeable Membranes & Waterproofing MiraPatch - Concrete Repair Mortars & Underlayments
Visit our website at www.miracote.com. Headquarters: 800.692.3502 West Coast: 310.631.6594 East Coast: 908.245.2808
Crossfield Products Corp. | miracote.com | 800.692.3502 | miracote@cpcmail.net 46 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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Turbo Blades combine the advantage of both continuous rim and segmented blades and can be used wet or dry. This type of blade can simulate the precision of continuous rim blades. soft aggregates cut faster and are easier to cut, i.e. require a harder metal bond. Depth The deeper the cut needed the bigger the blade required. Not all angle grinders can take all sizes, so consider the tool as well. Age Green concrete (0-8 hours old) requires a harder-bonded diamond blade than cured concrete (anything over eight hours), which requires a softer bond. Compressive Strength Hardness of concrete is measured in pounds per square inch (PSI). Roads, sidewalks patios, parking lots and indoor concrete tend to range from soft to medium. Bridges, piers and nuclear power plants are some of the applications that are hard or very hard. The higher the compressive strength, the harder the material and the softer the bond required for cutting. Steel content Rebar or wire mesh in concrete will cause slower cutting rates, reducing the blade life. Speed Consider the horsepower and operation speed of the angle grinder being used. Blade manufacturers provide charts with recommended operation speeds and maximum safety speeds for their blades, which is often laser etched right on the blade. Wet or Dry Make sure the blade can be used for the application needed. As a general rule, wet cutting is essentially an outdoor job due to the wetness around the saw; dry cutting is usually reserved for indoor jobs. So appropriate blade selection may require wet use, dry use or both. Never use a wet-use blade without cooling water or its life will be considerably shortened. As a rule of thumb, rely on the product packaging from the manufacturer when buying a blade for a specific application.
Photo Credit: Robert Bosch Tool Corporation “After 30 years of trying, Trinic’s StampShield put an end to my sealer callbacks. When a customer calls now it is to thank me for a job well done.” ROBBIE BAUMAN, BAUMAN BROTHERS CONCRETE 30 YEARS IN TRADE
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CUT and BEND REBAR At the Shop or Jobsite
#8 bar rotary bender/cutter combo
MEETING NEW REGULATIONS Every jobsite in America where concrete is cut, drilled or requires grinding changed on Mar. 24, 2016. That’s when the U.S. Department of Labor’s Occupational Safety and Health Administration (OSHA) ruling was announced that reduces worker exposure to respirable silica dust in an eight-hour period from 250 micrograms per cubic meter of air to 50 micrograms. After June 23, 2017, employers will be subject to OSHA review and penalty for non-compliance. To meet the guidelines, every jobsite will require a dust management solution or provisions for wet cutting of concrete.
Portable #6 bar cutter/bender
Replacement blades for most brands
www.RebarBlades.com
Quality rebar equipment since 1979
FASCUT Industries Inc. (608) 643-6678
www.fascut.com
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PRODUCT FOCUS Pro-V Series Diamond Blades Series includes: 12" and 14" laser-weld diamond blades, 4" to 7" segmented diamond blades, 4" to 7" turbo-rim diamond blades, 4" and 4-1/2" wet/dry tile blades, 7" to 10" wet tile blades and 4" and 7" double-row cup wheels • All lines offer fast cutting capability, high-tensile strength cores and tall diamond segments and rims ForConstructionPros.com/10084418 •
Norton GMAX Diamond Blades The Norton GMAX diamond blades are designed for early entry concrete cutting. • Exclusive universal arbor that allows usage on industry green saws • Anchor slot gullets of the blades reduce vibration • Blades' thick core and high segments resist flexing • Three blade types available for various aggregate hardness ForConstructionPros.com/10247555
Core Cut Star Blue The new Core Cut Star Blue grade segmented high speed blades can be used wet or dry to cut asphalt, green concrete, and soft materials with a high speed saw. The blade is available in 14 by .125 by 1 in. size with 20mm bushing. ForConstructionPros.com/10091742
OX Tools’ PU10 Diamond Blade The new OX PU10 cuts the most common materials found on a construction site. It cuts quickly due to its continuous rim design that features an edge that is serrated, giving the blade faster cutting speeds while maintaining a smooth cut. • The reinforced center plate offers increased safety while the vibration dampening means quieter cuts. • Available from 4" to 14", these blades can cut granite, natural stone, clay products, engineering bricks, concrete products and metal. ForConstructionPros.com/12234492
Nor’Easter MK-313 Diamond Blade MK Diamond Products designed its Nor’Easter MK-313 diamond blade with extra core cutouts, or cooling holes, are said to improve cooling during deep cutting and help keep the core from warping or losing tension. The blades are for wet or dry cutting of asphalt and concrete. • Laser-welded segments designed to withstand the heat and pressure of dry cutting • Combination of segmented and turbo segments cut abrasive materials like asphalt and concrete overlays • Available in 12- to 18-in. diameters • 15mm segment height offers long wear life ForConstructionPros.com/10847748
EDCO Brand Diamond Blades The Diamond Blade line from EDCO offers a wide range of diamond products compatible for EDCO, CONTRx and competitors’ saws and grinding equipment. • Blades for walk-behind, masonry, tile, circular, cutoff and crack saws • Also included are accessories for core drill rigs, concrete grinders and angle grinders • Blade labels display helpful information regarding blade compatibility, safety, installation and how to reorder ForConstructionPros.com/10219300
SEARCH for more information online using the unique URL under each product.
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THE LATEST PRODUCTS
NEW PROPANE GRINDERS & NEW LAVINA-X DUST EXTRACTORS
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PRODUCT FOCUS Husqvarna F1420C Diagrip From Husqvarna, Diagrip technology ensures diamonds are held in the blade’s segments longer and optimally distributed. This ensures a superior cutting capacity, longer life and smooth, rapid cutting. This technology can now be found in the F1420C Diagrip flat saw blade. It is made to cut hard concrete with steel reinforcement. ForConstructionPros.com/11466283
The Guardian Blade by DITEQ
Hilti SP and UP Diamond Blades
The Guardian blade by DITEQ features ARIX diamond arrangement technology for faster cutting speed and longer blade life. DITEQ’s super high-quality diamonds provide optimal segment strength in its three segment designs including a wear guard deep segment. The air-cooled structural core prevents overheating. • Designed for use on high speed, masonry and lower horsepower flat saws cutting cured concrete, green concrete, asphalt brick and block along with a wide variety of stone • Guardian blades are available in sizes ranging from 12 to 20 in. diameters ForConstructionPros.com/12029281
The Super Premium (SP) and Universal Premium (UP) Diamond Blades are designed for use with all Hilti hand-held diamond cutting tools. • SP blades with Equidist technology feature diamond segments each spaced at regular intervals to provide up to 50% faster cutting speeds and up to 50% longer life • UP blades cut a variety of base materials provide maximum versatility while delivering a high balance of speed and life ForConstructionPros.com/10634474
VISIT EDCO @ BOOTH NO. 702 January 29th thru February 1st South Point Casino Hotel & Convention Center, Las Vegas, NV
February 17th thru February 19th SEE EDCO in Anaheim, CA The ARA Rental Show - February 26th thru March 1st Orange County Convention Center, Ordando, FL
VISIT EDCO @ BOOTH NO 3346
SOLID STRONG CONCRETE EDCO’s Crete-Planers clean, texture, level, groove and remove. Crete-Planers are versatile milling machines that stand up to any required removal and prep work.
CPM-8 8” WALK BEHIND CRETE-PLANER edcoinc.com
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Gila Tool Premium Segmented Diamond Blade Gila Tools Premium Segmented Diamond Blades feature a segmented rim for faster and aggressive cutting on a range of masonry and construction materials. • Made from Hi-Grade diamond powder with a proprietary bond that is engineered for maximum cutting performance • Durable heavy-duty steel core construction • For use with angle grinders, circular saws, gas cut-off saws, masonry saws and walk-behind saws • Ideal for cutting concrete, brick, block, pavers, roof tile, natural stone and masonry • Great for dry and wet cutting ForConstructionPros.com/12178225
Lackmond Products Introduces PRM-RH Series Blade for Hard Materials Lackmond Products introduces the New PRM-RH Series blade. Lackmond’s PRM-RH Series hard materials blade is a mid-range product which combines high performance at a competitive price. The PRM-RH blade is designed to cut hard materials such as hard brick, hard concrete, river rock, granite, and more. It is engineered with a reinforced hub which ensures strait and accurate cuts on hard materials. • Designed to be used on both hand held and walk behind saws • Soft-bond matrix for use on hard materials • Very fast, aggressive, clean cutting • Long life • Use dry or wet ForConstructionPros.com/12109393
BOOTH B7213
HDX760
AT CON-EXPO/CON-AGG
10’ T4F DIESEL RIDER
Detroit Industrial Tool 40th “Anniversary Blade”
HDX760 HYDRAULIC RIDING TROWEL
T
T4
C
PLIAN OM
PARAGOULD, ARKANSAS, USA // 870.236.7751 // WWW.ALLENENG.COM
POWERED BY
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10’ rider equipped with a 74 hp T4F Hatz diesel engine and Bosch-Rexroth hydraulic components that talk to each other to provide unequaled performance.
R
Detroit Industrial Tool is a family owned and operated company celebrating 40 years as a leader in the Diamond Blade/Cutting Tool industry. To mark the 40 year milestone, the company has launched the “Anniversary Blade”, designed exclusively for Detroit Industrial Tool. This limited edition is a multi-application blade, engineered for fast, aggressive cutting of concrete, rebar, and other materials. The patterned cooling holes and unique segment design make this blade an essential tool in your arsenal of equipment. ForConstructionPros.com/12263990
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PRE-SHOW PRODUCT ROUNDUP
ConExpo PREVIEW
A compilation of products from scheduled exhibiting companies. HoistCam Director and Cameras to Aid Concrete Placements
Pettibone Extendo 944B Telehandler
The HoistCam Director enterprise fleet monitoring software enables construction owners and managers to remotely monitor an entire jobsite via HoistCam, SiteCam and other cameras or drones. • Transfers video and images to a mobile digital video recorder (MDVR), which captures and stores data from up to eight HoistCam cameras
The Extendo 944B delivers a 9,000-lb. maximum load capacity, forward reach up to 30 ft. 3 in. and a maximum lift height of 44 ft. 4 in. • Fuel-efficient, 117-hp Cummins QSF 3.8 Tier 4 Final turbo diesel engine features electronic control and protection with selective catalytic reduction aftertreatment • Dana T12000 Powershift series transmission offers three speeds forward and reverse • Four-wheel, two-wheel and crab steering modes, with a turning radius of just 12 ft. 4 in. • Offers 24° of frame sway (12° left and right of center) and is equipped with a rear axle stabilization system • Incorporates two wide-stance, heavy-duty lift cylinders with automatic fork and load leveling, single joystick, pilot-operated controls and Parker IQAN-MD3 display ForConstructionPros.com/12136554
•
CONEXPO Booth #N11541
CONEXPO Booth #G71913
Customizable alarms and interfaces include geofencing, Shock/G-Sensor, temperature sensor, voltage output triggers and RS485/ RS232 monitoring • Provides a choice of cellular, Wifi or Ethernet communication, site tracker services with custom safety or logistics reports and storage on in-house servers or HoistCam-hosted servers ForConstructionPros.com/12278656
VT-70 is ASV's First Mid-Frame Vertical-Lift Compact Track Loader ASV LLC, a manufacturer of allpurpose and all-season compact track loaders and skidsteers, introduces the company’s first mid-frame, vertical lift compact track loader, the Posi-Track VT-70. The machine features a vertical lift loader linkage for applications requiring extended reach and level loads. • Features a Kubota 2.4-liter turbocharged diesel engine. The 65-horsepower engine produces 146 foot-pounds of torque. • The VT-70 features a rated operating capacity of 2,328 pounds and a tipping load of 6,650 pounds. It is 66 inches wide and has a 10.5foot lift height. • Standard joystick controls make operation easy and intuitive. • Operators can use the unit with all standard attachments ForConstructionPros.com/12294141
CONEXPO-CON/AGG Booth #G4464
New Schwing S 38 SX Has Unique 5-Section Boom
The 265-lb. MC200 Multi Cutter steel cutting attachment is designed for use on machines weighing 2,650 to 6,170 lbs., including the Brokk 100, 120D and 160 models. • Uses a hydraulic booster to exert 50 tons of cutting force at 3,900 psi • 8-in.-wide jaw opening • Hydraulic 360° rotary drive for exact positioning • Measures 10" x 13" and 40 in. long ForConstructionPros.com/12285130
The S 38 SX with five-section boom offers added articulation on the working side of the boom for faster deployment and the ability to snake the end hose deep into decks. • Boom provides 106 ft. 11 in. of horizontal and 122 ft. 4 in. of vertical reach • Open-loop, twin-cylinder hydraulic pump offered in two sizes with output up to 216 cu. yds. per hour • Super X-style front outriggers can be deployed on one-side only for setup • Standard EASy system narrows footprint further and provides up to 180° of boom rotation on the pour side • Available in a three-axle configuration with cabover truck or four-axle version with conventional truck to meet federal bridge laws ForConstructionPros.com/12276315
CONEXPO Booth #G72914
CONEXPO-CON/AGG Booth #B7517
Darda Multi Cutter Attachment Enhances Brokk Machines’ Versatility in Steel Cutting
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•
$ WIN 100 Booth #N-11825 North Hall
just for wearing your CASE safety vest at
It Pays to Stand Out
It’s easy to win BIG. Pick up your free ANSI-approved safety vest from CASE booth N-11825 and wear it during CONEXPO-CON/AGG & IFPE. Attendees wearing the vests will be selected at random to win $100 CASH! The ANSI-approved vest is yours to keep – take it home and wear it on the jobsite. $6,500 in prizes will be awarded during the show but you must be wearing the vest to be eligible to win. Supplies are limited.
Brought to you by ForConstructionPros.com and AC Business Media. CASE is the official vest sponsor for this program.
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Increte Systems Introduces Clear Seal Natural
GorillaConcreteTools GCT-4.5 Crack Chaser
GCT-9 Silverback Joint Saw & Crack Chaser
GCT-10 Joint CleanOut Saw
The Euclid Chemical Company is proud to introduce a new sealer to its Increte decorative line. Clear Seal Natural is a water-based, siliconized, nonfilm forming water-repellent. Clear Seal Natural provides an invisible shield of superior water and stain repellency while leaving the surface natural looking with no coating or gloss. Perfect for stamped concrete, integrally colored surfaces, pavers, stone, and more. It’s color enhancing technology renews older surfaces and makes new surfaces pop to life. Long lasting and durable, it stands up to the blistering Southern sun and the freezing Northern climates. Features and benefits: • Color enhancing • Breathable • Low VOC, low odor • Can contribute to LEED points (EQ Credit 4.2) ForConstructionPros.com/12281018
CONEXPO Booth #S60907 clean-out, diamond, crack chasing and tuck-pointing blades
800.896.8665 • www.runyonsurfaceprep.com
Worksaver, Inc. SSGB8B Grader/ SS-590 Skid Steer Mixer The patented SSGB-8B Grader is designed for concrete flatwork, asphalt and landscaping contractors. The unit features an 8 foot six-way hydraulically controlled moldboard with 25-degree rotation/tilt is controlled with an in-cab remote for precise control. The moldboard is shear pin protected to help prevent damage. With an optional laser system, the grader will maintain grade to tight tolerances. Worksaver also offers other products including the SS-590 Skid Steer Mixer which is ideal for all mixing jobs. • Features a large 11 cu./ft. drum to mix, transport and place 5 cu./ft. of concrete. • The direct hydraulic drive of the gearbox eliminates chain and sprocket maintenance, offering more up-time on the jobsite. ForConstructionPros.com/12289927
CONEXPO Booth #G71225
Allen Introduces the New HDX760 HydraDrive Extreme Riding Trowel › › › › › › › › › Unrivaled Quality › › › › › › › › › › › › › › › › › › Proven Reliability › › › › › › › › › › › › › › › › › › Superior Service › › › › › › › › ›
Commitment to Excellence Phone: 800-678-8006 www.ditool.com
Allen a manufacturer of site prep and concrete finishing equipment, announces the debut of their new HDX760 Riding Trowel. The HDX760 is a state-of-the-art, hydraulically controlled ride-on power trowel that incorporates “Intelli-Power” to ensure peak performance, component safety and extended life. The built-in “Intelli-Power” system controls both the hydraulics and the engine operation. HDX760 standard features include: • Hatz 4H50TIC (T4F) 74 hp diesel engine • Bosch-Rexroth Hydraulic system • Electric (Joystick mounted) single or dual pitch capable • Rotor Speeds up to 145 RPM • Two point, top-mount lifting system • Twin, 57.6” Rotors with six bladed spiders ForConstructionPros.com/12287253
CONEXPO Booth #B7213
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PRE-SHOW PRODUCT ROUNDUP Exclusive: Wacker Neuson's New Medium-frame Loaders Rise From the Ground Up Wacker Neuson's new line of four medium frame skid steers and two compact track loaders feature class-leading hinge pin height on the vertical loaders for maximum loading and unloading capabilities. • 221 lbs. engine torque • Kohler diesel engine feature regeneration-free aftertreatment system • Universal skid steer attachment plate • 30-gal. fuel tank • 20 gpm auxiliary standard hydraulic flow ForConstructionPros.com/12289906
CONEXPO-CON/AGG Booth #G3435
MAX USA CORP. Introduces the New RB398 The RB398 is capable of tying rebar up to #6 by #5 and also double #4 by double #4 with up to 2,600 ties per charge. • 4.0-Ah 14.4v lithium-ion battery • Features a brushless motor, trigger lock, torque adjustment dial, reversible belt hook, carrying case and automatic shut-off • Standard charger and battery pack • Designed for simple operation ForConstructionPros.com/12157520
CONEXPO Booth #G73214
Oztec BP50a Backpack Concrete Vibrator The BP50a backpack concrete vibrator now has CE Mark approval certifying it has met EU consumer safety requirements. The vibrator features a totally enclosed rotary throttle that prevents wet concrete from entering and clogging the throttle mechanism. • Will run steel and rubber vibrator heads up to 2 1/2 in. • Vibrator heads develop 12,000 vpm and never drop below 10,000 vpm • Standard Quick Disconnect "QD" system, Honda gasoline engines and "speed-up" transmission • Kill switch conveniently located on the handle ForConstructionPros.com/10082973
CORE DRILL & RIG SYSTEM
European Made! To p Quality! 3-Speed performan ce gearing LED Motor overload protection Data retrieval softw are
800-850-2044 | Lackmond.com
CONEXPO Booth #S62628
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FOUNDATION Q&A
By James R. Baty II
Confirming the Connection Detail for a RESIDENTIAL
FOOTING This column is an expansion of the footing detail discussion offered in the December 2016 edition. In this issue, a CFA member asks for an interpretation of the cover requirements for dowels in a footing used to provide connection between the concrete footing and the foundation wall. In the last column, I responded to a condition where an inspector assumed the vertical dowel connection and vertical steel in the foundation wall must be detailed to the footing with a standard hook, whereby it was identified that this is an IRC1 requirement for higher seismic categories only. This column adds to the discussion of proper dowel detailing, particularly when dowels are wet set into the footing, using the minimum requirements set forth by ACI 332-142, a reference standard considered an acceptable alternative to the provisions of the IRC. This is a specific condition where the detail requirements of the ACI document provide greater clarity to a condition not made clear by the
general residential building code for residential concrete foundations.
Q
I thought that wet sticking vertical steel as shown in the attached photo has been addressed or is approved by the CFA and/or ACI. Am I correct in this assumption? A private home inspector, hired by the buyers, has referenced ACI and the lack of proven concrete cover at the ends of the vertical steel bards. Asserting that potential corrosion presents a serious concern to the longterm durability of the footing and foundation, he is recommending that the footing should be removed and replaced. What does the code say on this? My client, the concrete contractor, must now defend this practice of wet sticking the vertical steel reinforcing bars. The vertical bars in the photo may or may not have the minimum required 3-in. concrete cover at the bottom end of the bars.
A
NSWER: The photo presents several conditions addressed by ACI 332-14 and by ACI 332R-063 that are worthy of discussion and to which resolution of this argument can be found. Before addressing that, it should be clarified that ACI 332-14 requires concrete cover over reinforcement of 0.75 in. for any interior exposed element, 1.5 in. when exposed to the exterior and 3 in. for any concrete surface that is in contact with the ground. Reinforcement consists of the horizontal steel prescribed for temperature and shrinkage crack control as well as the vertical steel prescribed when necessary for flexural forces exceeding the concrete’s modulus or rupture. It is first important to understand that ACI 332-14 has permitted driving the vertical dowel connection into the sub grade for pre-positioning the dowels ever since the 2004 edition. The relevant section in 332-14 states: 7.3.4 Wall-to-footing joint—Wallto-footing connections located in SDC A, B, or C shall be constructed in accordance with 7.3.4.1 or 7.3.4.2. Wall-to-footing connections located in SDC D, E, or F shall be constructed in accordance with 7.3.4.2. 7.3.4.1 A vertical No. 4 dowel shall extend at least 36db into the wall and 6 in. into the footing at a maximum of 24 in. on-center along the footing. To facilitate positioning before concrete Figure 1: Footing for private residence with vertical wall reinforcement wet set in footing. Photo Credit: Concrete Foundations Association
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Figure 2: Footing detail showing minimum requirements from ACI 332-14 for lateral connection by dowel. Photo Credit: Concrete Foundations Association
placement, vertical dowels are permitted to be driven into the grade in the bottom of the footing. In this section, 332-14 clearly provides for vertical dowels that do not conform to the requirements of concrete cover. The dowel is not considered reinforcement but rather the positive connection or anchor between the footing and foundation wall. It is for lateral support only. The guide document companion to the code (ACI 332R-06) further explains this condition stating: 3.8.6 – The dowels should extend at least 12 in. (300 mm) above the top of the footing, and 6 in. (150 mm) into the footing. If the depth of the footing is not adequate to develop a straight bar into the footing, the bottom of the dowels can be hooked. Unless prohibited by local code, the dowels may be pushed into the fresh concrete (also referred to as wet setting of dowel) immediately following striking the
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FOUNDATION Q&A
Figure 3: Footing detail showing minimum requirements from ACI 332-14 for lateral connection by keyway. Photo Credit: Concrete Foundations Association
final level or they may be positioned in the footing form by driving them into the subgrade before concrete placement to maintain their vertical and horizontal positions as well as alignment. Either concern is covered by these sections of the code. The act of wet setting the steel is not prevented by the code and further examined by the common practices found in the guide. The code only restricts the minimum dimension of the steel connection into the footing (6 in.) and permits the steel extending through the concrete into the grade. Therefore, offering wet setting where confirmation of coverage is not attainable or driving it through the concrete into the grade. Your photo shows a couple other details that need to be noted. A keyway has clearly been formed into the top of the footing, but the dimensions of this cannot be fully determined for compliance. ACI
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58 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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332-14 provides for an option to the dowel connection of wall to footing as noted in 7.3.4 with the following: 7.3.4.2 A continuous keyway shall be formed in the footing and shall be located within the middle third of the wall. The keyway specified dimensions shall be at least 1-1/2 in. deep and 1-1/2 in. wide at the top. 7.3.4 directs that either a dowel connection to the footing or a keyway connection is to be used and therefore it is not necessary to have them both. It becomes apparent with both details in your photo, the intent was to use the keyway for lateral stability of the footing/wall joint and the vertical “dowels� are in fact the pre-positioned vertical steel for the wall. This is where the interpretation of the code should be attended to carefully. While the lack of concern for steel corrosion affecting the longterm behavior of the footing, the fact that the tall vertical bars are likely
intended to serve as flexural steel makes them reinforcement and therefore easily interpreted to be required to have cover maintained. To attend to this in the most effective and efficient manner without the needless waste or resources, time and energy to tear the footing out and start over, it would be proper to cut the vertical bars at 12 in. (or 36db) above the top of the footing. This would make them clearly dowels and an extra detail to the presence of the keyway, or the alternative if there is concern the keyway does not meet the minimum profile noted in 7.3.4.2. The contractor should then proceed by tying vertical bars to the required horizontal steel for support and consistent spacing. These would be disconnected and unrelated to the dowels and therefore not subjected to interpretation of concrete cover related to the bottom of footing.
References: 1. 2015 International Residential Code For One- and Two-Family Dwellings published by the International Code Council, Inc., 4051 West Flossmoor Road, Country Club Hills, IL 60478-5795 | Phone 1-888-422-7233 | www. iccsafe.org 2. Residential Code Requirements for Structural Concrete (ACI 332-14) and Commentary published by the American Concrete Institute, 38800 Country Club Drive, Farmington Hills, MI 48331 | Phone: 248-8483700 | www.concrete.org 3. Guide to Residential Concrete (ACI 332R06) published by the American Concrete Institute, 38800 Country Club Drive, Farmington Hills, MI 48331 | Phone: 248-8483700 | www.concrete.org
Ed. Note: Jim Baty is the Executive Director of the CFA and can be reached at (866) 232-9255 or by email at jbaty@cfawalls.org. ACI 332-14 can be obtained by contacting the CFA or by visiting the American Concrete Institute (www.concrete.org) and ordering from their bookstore.
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www.forconstructionpros.com/concrete | January/February 2017 | Concrete Contractor 59
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CONCRETE WATERPROOFING
By Del Williams
Rehabbing Aging Concrete Wastewater
INFRASTRUCTURE Advanced polyurea coatings and liners provide strong, flexible waterproofing to bridge cracks and protect against future cracking and deterioration.
A
s much of the nation’s wastewater and sewer infrastructure approaches the 50-100 year mark, it must be rehabilitated to remain in use for a growing population. Yet municipal wastewater treatment facilities, sewers and vaults endure some of the most severe and corrosive environments in the water industry and must pass increasing Environmental Protection Agency (EPA) scrutiny. At industrial plants as well, EPA enforces requirements to ensure that industries pre-treat pollutants in their wastes to protect local sanitary sewers and wastewater treatment plants. Such extreme wastewater handling environments operate under continual chemical exposure and heavy abrasion that deteriorate concrete and corrode steel in clarifiers, containment pits, anaerobic digesters, manholes, tanks and other infrastructure assets. A variety of factors can cause these structures to develop sizable
cracks through which wastewater can escape (exfiltration) or groundwater can enter the wastewater system (infiltration). Leaks, cracks and damage to existing coating systems not only top the list of challenges in facility maintenance and new construction, but can also trigger severe penalties if municipalities or industrial facilities are found in violation of EPA judicial consent decrees. Fortunately, advanced polyurea coatings and liners are proving ideal for wastewater infrastructure rehabilitation by delivering strong, flexible, abrasion and chemical-resistant waterproofing that not only bridges existing cracks, but can elongate up to 400 percent without cracking. Because they set and cure rapidly, and can be installed and used in a wide range of temperatures, they also minimize facility downtime.
CONCRETE CRACKING AND DETERIORATION Cracks can develop in aging concrete wastewater infrastructure for a number of reasons ranging from earth movement to daily or seasonal temperature changes that cause expansion and contraction including freeze-thaw. Additionally, harsh chemicals used to treat wastewater can deteriorate the concrete, as can exposure to hydrogen sulfide gas, a form of sulfuric acid present in sewers created by anaerobic organisms. Since the EPA regulates municipal wastewater and storm water management, concrete cracks or leaks that lead to wastewater exfiltration or
groundwater infiltration can put the municipality in violation of a judicial consent decree, triggering significant penalties. Consent decrees are settlements in judicial actions that are signed by all involved parties and filed in the appropriate court. “If the EPA finds that a municipality has old leaking sewer systems, putting them on a consent decree can mean that they don’t receive federal tax money until the problem is fixed,” says Jim Osborn, president of Osborn Contract Services Inc., a
60 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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Advanced polyurea coatings and liners are ideal for wastewater infrastructure rehabilitation by delivering strong, flexible, abrasion and chemical-resistant waterproofing. Photo Credit: VersaFlex Inc.,
Polyurea coatings set and cure rapidly, enabling them to be installed and used in a wide range of temperatures, they also minimize facility downtime. Photo Credit: VersaFlex Inc.,
South Carolina-based certified applicator of spray applied coatings and rehabilitation products. According to Osborn, a cementitious material is traditionally used to repair wastewater-related sewer leaks, but this has disadvantages, as do other coating materials. “Hydrogen sulfide gas eats away at the cement in sewer concrete, so it may only have a lifespan of a few years,” says Osborn. “Because epoxies are limited by much lower elongation properties, they crack and don’t
bridge cracks well. Polyurethanes have more elongation, but nothing like polyureas.” For concrete repairs in wastewater infrastructure from municipal manholes and lift stations to clarifiers, trenches and sumps, Osborn has transitioned to an advanced polyurea system from VersaFlex, a manufacturer of spray applied protective coatings and waterproof membranes for the U.S. wastewater and industrial markets. The spray applied waterproof coating creates a seamless,
waterproof, durable protective liner that stops leaks and strengthens the integrity of the entire structure. It exhibits superior physical properties such as elongation up to 400%, crack bridging, hardness, and tensile strength to create a robust industrial liner that protects, strengthens, and waterproofs concrete wastewater infrastructure. According to Osborn, a number of the polyurea’s characteristics help to extend wastewater infrastructure longevity as well as prevent wastewater exfiltration and groundwater infiltration. “Since the polyurea system provides superior elongation, it bridges cracks up to 1/8”, says Osborn. “With tensile strength higher than traditional materials, it has much lower permeability for better waterproofing. Its impact, abrasion, and chemical resistance are excellent so it resists hydrogen sulfide. Instead of years between the replacement of cementitious coatings, the polyurea coating can cost-effectively provide decades of protection.” With the proper crack repair and surface preparation, the polyurea coating can be a thick film applied directly to the concrete or similar substrate. An alternate application method that can sometimes mitigate the need for surface or crack repairs is to pre-spray the polyurea to geotextile fabric panels placed above the onsite substrate, fusing the panel edges together with more polyurea. Because of the polyurea’s ability to set and cure quickly, it also
www.forconstructionpros.com/concrete | January/February 2017 | Concrete Contractor 61
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CONCRETE WATERPROOFING minimizes wastewater treatment plant or infrastructure downtime. This can translate into thousands of dollars per hour savings as well as avoiding days of service interruption. When extensive cracks were found in a concrete clarifier shortly before a chemical plant’s ribbon cutting ceremony, Osborn turned to the polyurea for superior protection and fast installation. After repairing all cracks over 1/8” wide in the clarifier with a concrete repair grout, Osborn prepared, then primed the floor and walls with VersaFlex VF 20 primer, and applied 80-100 mils of FSS 45DC polyurea. “The polyurea allowed us to provide a warranty against potential future cracks opening in the concrete because of its crack bridging ability,” said Osborn. “We were able to spray the polyurea as thick as needed in one application. Since it sets and cures rapidly, structures can put be back in service very soon after spraying.”
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A variety of factors can cause these structures to develop sizable cracks through which wastewater can escape (exfiltration) or groundwater can enter the wastewater system (infiltration). Photo Credit: VersaFlex Inc.,
While traditional coatings such as cementitious, epoxies, and polyurethanes will prematurely fail if not installed under a relatively narrow range of temperatures, the polyurea is designed for installation and use from -40°F to +350°F. It will withstand decades of freeze-thaw cycling, and wide variations of temperature and humidity. “When you’re above ground in the Midwest, you have freeze and thaw with concrete expansion, contraction, and cracking,” says Jennifer Hoop, President of Conco Spray Solutions, an Indianapolis-based contractor specializing in the rehabilitation and protection of municipal infrastructure including potable, storm and wastewater systems. “We needed a lining that would move with the structure through the different seasons and tank temperature differentials. For that, polyurea works very well.” To withstand extreme weather conditions at a northern Indiana wastewater treatment plant, Hoop selected the polyurea for a secondary containment area around ferric chloride tanks. “After filling in cracks with grout and restoring the concrete, we sprayed the polyurea on geotextile to provide a really nice containment area for the ferric chloride tanks,” she says. Hoop, whose company does a large amount of wastewater-related work on containment, clarifiers, tanks and wet wells, says that the polyurea has an added
Advanced polyurea systems are available from VersaFlex, a manufacturer of spray applied protective coatings and waterproof membranes for the U.S. wastewater and industrial markets. Photo Credit: VersaFlex Inc.,
benefit in reducing continual clarifier maintenance. “Typically clarifier maintenance crews need to use high-pressure power washers for hours to clean solid waste from concrete surfaces,” says Hoop. “Since the polyurea provides waterproofing and has a cleanable surface, crews can simply hose down the clarifier to clean it. This can cut required weekly clarifier cleaning by two-thirds.” “For wastewater-related rehabilitation, polyurea is a superior coating for any application that requires crack bridging, longevity, chemical and temperature resistance, as well as fast turnaround,” concludes Hoop. Ed. Note: Del Williams is a technical writer based in Torrance, California. He writes about health, business, technology, and educational issues, and has an M.A. in English from C.S.U. Dominguez Hills.
62 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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www.forconstructionpros.com/concrete | January/February 2017 | Concrete Contractor 63
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WOC Idea File
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64 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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www.forconstructionpros.com/concrete | January/February 2017 | Concrete Contractor 65
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THE LAST PLACEMENT: BACK TO BASICS
N
Steps to Improving Mediocre Workers
o contractor I know will ever admit to purposely recruiting mediocre workers. Yet, many of the same contractors do admit to having a great many workers who are far from excellent or who have no motivation to learn. Welcome to the reality, the nightmare really, of working with mediocrity. One definition of mediocrity is: “A person who does not have the special ability to do something well.” It’s worth addressing how to deal with those employees you consider to be mediocre in their work habits, performance, and results. There are several actions you can take to make sure you are bringing out the best that is possible from those workers who may be “performance challenged.” Spend Additional Time Spelling Out Daily Expectations. Setting out the week’s schedule might work for your best performers, but for the mediocre worker a daily dose of “what we are going to do today” cannot be overemphasized. Turn Follow-up into a Quarterly Habit. If you “quarter-up” your day you will find that there are about four 90-120 minute sections of time. During each “quarter” you should tour your work areas to make sure that workers, especially your mediocre workers, are doing what they were assigned to do. Build on Every Positive Demonstration of Productive Movement. You need to reaffirm each and every positive effort put forth by those who don’t set the bar of performance excellence as high as they need to. Such positive reinforcement can go a long way to winning these folks over
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By Brad Humphrey
to putting out more effort and possibly nudging their performance bar higher. Keep the Bar High on Productivity, Quality & Commitment to Excellence. Don’t allow mediocre workers to subtly dictate that some days on the job will not be great. Shoot for greatness every day and on every project. Let your guard down just a little here and you will have a project go south on your faster than you can shake a stick. Don’t Settle for Less-thanNeeded Results. OK, let’s face it: Not everything that even our best workers do is perfect…every time. However, when the results are not quite there and reworking will not cost you too much…do the rework to make sure your workers realize the seriousness of doing things right the first time. Engage Your Customers to Give Workers Feedback on Their Results. Often what a customer might say can have more impact on workers than anything an owner might try to communicate. The boss can discuss how important quality is all day and not raise an eyelid from workers; but have a customer say the same thing and suddenly the workers are knocking themselves out trying to meet the customer’s expectations. Engage More of Your Mediocre Workers in Job Reviews & Best Practices Learned. Because many mediocre workers often display little interest in getting better, contractors will naturally focus improvement discussions on workers who appear to care about job quality and improving their skills. This can be a huge mistake. Often the mediocre folks are exactly the people who need to be brought into discussions about “how to make things better.” Including them in
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post-job reviews and discussions of best practices can help them feel like they are part of something that welcomes them and their ideas. Engage Your Mediocre Workers Face to Face. It is very common for mediocre workers to feel like they are just a number. For many, this is a comfortable existence because it doesn’t single them out and it doesn’t make an example of them. However, by pushing past this and actually engaging your mediocre workers -- face to face -- you are challenging them to listen, to step up, to do something beyond just showing up to work and moving through the motions. This effort will “arm twist” your worker to respond and to react to your proactive effort. OK, I know that for many workers of mediocrity not one of these eight suggestions will have the desired result. But your effort may still connect with some of your workers. Sure, you can just terminate the mediocre employees. But you might be surprised how many workers you tagged as mediocre will actually become engaged – and improve on the job -after your efforts. We all employ mediocre workers. In fact, some of our best mediocre workers have been with us for five, 10, 15 or more years. So, instead of complaining about them, let’s engage them.
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Brad Humphrey is President of Pinnacle Development Group, a consulting firm that specializes in the construction industry. Pinnacle offers a new educational App, available through www.pinnacledg.com or your App Store (type in Pinnacle Development Group).
66 Concrete Contractor | January/February 2017 | www.forconstructionpros.com/concrete
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