Micro-Toppings Offer an Array of Decorative Finishes
36 April/May 2015
Now available online and on your iPad!
The Rise of
Tilt-Up Concrete 20
SPECIFICATION GUIDE: Screeds 26
48 www.forconstructionpros.com/concrete
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April/May 2015 | Issue 3, Volume 15
WHAT’S INSIDE
Cover Story 20 Acceptance of Tilt-Up Concrete Continues to Rise
Features
42 How to Justify Capital . Equipment Cost
12 What to Do About Dominant Joints in Floors A rare case where doing all the right things can make the problem worse.
As your market improves, you may find yourself wrestling with whether or not it makes sense to own your own concrete pump.
24 Concrete Foundations . Association Introduces Industry Specific 48 What’s Old Becomes Insurance Program New Again What it means for the concrete contractor.
36 Micro-Toppings Offer a Wide Array of Decorative Finishes The versatility of concrete microtoppings offer contractors options to create various effects with few limitations.
40 Decorative Surface Solutions Group Aims to Capitalize on Growth The introduction of a buying/ marketing group focused on four distinct concrete market segments hopes to improve the industry and bring together suppliers and contractors.
A hospital floor deemed unfit to polish is restored due to the application of a decorative, polishable overlay wear topping designed specifically for such situations.
52 Dust Collection Equipment 54 The State of Maintenance and Polished Concrete Floors As a contractor, understanding the maintenance procedures and its role in your contracting work will lead to greater success.
Departments 4 Editor’s Letter 6 Challenging the System 8 New Products 26 Specification Guides: Screeds 46 Foundations Q&A 58 The Last Placement
What’s Online Read these online exclusive articles at www. forconstructionpros.com/concrete
Legal Matters Use Focus Questions for Better Hires Search: 12057027
Business 101 Fishing in Some New Ponds Search: 12057104
www.forconstructionpros.com/concrete | April/May 2015 | Concrete Contractor 3
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EDITOR’S LETTER Published by AC Business Media Inc.
Train Your Workforce
201 N. Main Street, Fort Atkinson, WI 53538 (800) 538-5544 • www.ACBusinessMedia.com
www.ForConstructionPros.com/Concrete
For new hires, how do you train your newest, inexperienced employee?
A
s the editor of Concrete Contractor magazine, one of the most enjoyable aspects of my job is the opportunity to chat with contractors from all over the United States. Over the last several months, I’ve spoken with contractors on the West coast, the East coast, and a few in between. In most instances, I am told similar accounts of a concrete contracting company looking ahead to the construction season, gearing up for a record breaking year and looking for new employees. The one question that continues to linger is “How are you recruiting and retaining a qualified workforce?” Some contractors told me they are utilizing local job fair events, while others are ramping up their workforce through referrals. In some communities, contractors are luring away employees from competing firms with promises of increased pay and expanded benefits. But what about that new employee who is fresh to the concrete industry and who may not possess the skills and knowledge of their veteran counterparts? Where will that individual learn the job? Most likely on the jobsite. I know of one contractor in the south-eastern part of the U.S. who spends the first Facebook.com/ ConcreteContractor
Advisory Board
Ryan Olson, Editor ROlson@ ACBusinessMedia.com (800) 538-5544
week with new hires showing them how to use a shovel, a hammer, and other tools of the trade. How do you train your new employees who have no experience in concrete work? I’d like to hear from you. Drop me a line at rolson@ acbusinessmedia.com. We’re excited to introduce the newest column to Concrete Contractor. Located on the last page of the issue, we present, “The Last Placement: Back to Basics”. This monthly column will feature basic, how-to topics geared toward the beginner concrete contractor. However, if you’re a veteran contractor, the topics presented here may be a good refresher course for you as well. If there is a specific topic you would like to see, please let me know.
P.S. - Concrete Contractor is now available as an IPad App. Visit the Apple Store and search “Concrete Contractor” for access.
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. Joe Reardon SASE Orlando, Fla.
4 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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PUBLICATION STAFF
Nancy Terrill, (800) 538-5544, ext. 1248 nterrill@ACBusinessMedia.com Ryan Olson, (800) 538-5544, ext. 1306 rolson@ACBusinessMedia.com Kim Basham, Jim Baty, Brad Humphrey, David C. Whitlock, Joe Nasvik Ad Production Manager Cindy Rusch Art Director April Van Etten Sr. Audience Development Manager Wendy Chady Audience Development Manager Tammy Steller Publisher Editor Contributing Writers
ADVERTISING SALES (800) 538-5544
Jill Draeger Eric Servais Erica Finger Amy Schwandt Sean Dunphy Denise Singsime National Automotive Sales
jdraeger@ACBusinessMedia.com eservais@ACBusinessMedia.com efinger@ACBusinessMedia.com aschwandt@ACBusinessMedia.com sdunphy@ACBusinessMedia.com dsingsime@ACBusinessMedia.com Tom Lutzke, tlutzke@ACBusinessMedia.com (630) 484-8040
FORCONSTRUCTIONPROS.COM
Digital Operations Manager Digital Sales Manager Editor Managing Editor
Nick Raether nraether@ACBusinessMedia.com Monique Terrazas mterrazas@ACBusinessMedia.com Larry Stewart lstewart@ACBusinessMedia.com Kimberly Hegeman khegeman@ACBusinessMedia.com
CHANGE OF ADDRESS & SUBSCRIPTIONS
PO Box 3605, Northbrook, IL 60065-3605, Phone: (877) 201-3915 Fax: (800) 543-5055 • circ.ConcreteContractor@omeda.com REPRINTS Nick Iademarco at Wright’s Media (877) 652-5295 ext. 102 niademarco@wrightsmedia.com. LIST RENTAL Elizabeth Jackson, Account Executive, Merit Direct LLC, Phone: (847) 492-1350 ext. 18 Fax: (847) 492-0085 • ejackson@meritdirect.com AC BUSINESS MEDIA INC.
Chairman President and CEO Executive Vice President CFO VP Content VP Marketing
Anil Narang Carl Wistreich Kris Flitcroft JoAnn Breuchel Greg Udelhofen Debbie George
Published and copyrighted 2015 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 1545-4193) 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 April/May 2015. Issue 3, Volume 15 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. Concrete Contractor is the Official Media Sponsor of the CFA Foundation Company Certification Program
®
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Top that! Ultratop 速 PC High-performance, polishable concrete topping
Ultratop PC is a high-flow, quick-setting, self-leveling, cementitious topping optimized for polishing. Suitable for both interior and exterior use, Ultratop PC is designed to be applied at 3/8" to 2" (10 mm to 5 cm) thick and cures quickly for fast-track resurfacing and polishing of concrete floors. Ultratop PC is suitable for applications including high-end residential units, retail stores, warehouses, schools, kitchens, airport hangars and loading docks. Ultratop PC is engineered to provide a thin resurfacing material that is extremely dense, hard and durable so that it is capable of holding a brilliant polish.
Contact your local Concrete Restoration Systems sales representative for more information or visit www.mapei.com.
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CHALLENGING THE SYSTEM
Ward R. Malisch, PE, PhD, FACI is concrete construction specialist for the American Society of Concrete Contractors. Reach him at wmalisch@ascconline.org.
How to Make an Irrational Inspector RATIONAL
Bruce A. Suprenant, PE, PhD, FACI, is technical director for the American Society of Concrete Contractors. Reach him at bsuprenant@ bsuprenant.com.
Five ways a contractor can challenge an inspector.
I
nspectors are usually competent, hard-working, qualified individuals. But over the last 30 years contractors have sometimes complained about inspectors who can’t be described using those three qualities. After explaining their situations, the contractors would then ask for our advice. Unfortunately, we couldn’t provide much help. We’ve heard a few creative solutions for this problem and we’re sharing them so you can possibly make an irrational inspector rational. What makes an inspector irrational? For the most part, we’ve heard from contractors that the inspector won’t play by the rule book — the contract documents. For instance, while the contract documents allow tolerances, the inspector won’t. We heard recently of one case where drawings showed the top rebar mat at 3 in. below the top surface. The rebar mat was measured to be at 2-7/8 in. below the surface but the inspector required a replacement because it wasn’t exactly at 3 in. as shown on the drawings. That’s just one example of an irrational inspector. So how can contractors deal with the problem?
OPTION 1: MEETINGS Ask for a meeting to see if other members of the construction or design team, or the owner, can understand why the inspector is being unreasonable. This is rarely effective because the contractor
is often the only member of the construction team who’s willing to speak up and say anything negative about another team member.
being on camera has changed some inspector’s behavior.
OPTION 2: CHALLENGE THE INSPECTION REPORTS
Contractors sign agreements that require them to construct in accordance with the contract documents. But if the contract documents allow for tolerances and the inspector does not, then this is a changed condition or modification of the contract. Based on this change, contractors can file a change order asking for more time and money to accommodate the change. Because the management side is not interested in considering any change in money or time, they typically have a conversation with the field side to discuss the issue. As a result of this conversation, we have seen a change in the field side. Sometimes we suggest increasing the impact of the change order by submitting a consultant’s report noting the changed conditions or modifications as shown by the inspection reports or non-compliance reports (NCR’s). We have heard from a few for which the inspection process improved. Be aware that all of these challenges to the inspector might make things worse. The contractors we talk to, however, often say things couldn’t get any worse and are willing to take the risk of challenging the inspector. Please share your stories of successful or unsuccessful counter-measures so we can improve our ability to recommend methods for making an irrational inspector rational.
Get a consultant to write a letter stating that the inspector is not providing appropriate inspection comments or is requiring changes not appropriate for the contract documents. Sometimes this works because the opinion of an outside consultant carries more weight and can be presented as evidence of the contractor’s efforts to rectify a problem.
OPTION 3: SHADOW THE INSPECTOR Recently we have heard from contractors who hired a consultant for a week to shadow an inspector. The consultant took photos of what the inspector saw, making notes about what the inspector said and directed. The contractor would then submit the consultant’s report as evidence concerning the inspection process. We heard this is somewhat effective.
OPTION 4: VIDEO THE INSPECTION PROCESS Again a contractor told us that he has installed GoPro cameras on two of his foremen’s hard hats to document the inspection process and all conversations by video. Contractors might consider buying these as an innovative method for documenting the inspection process. We’ve heard
OPTION 5: SUBMIT A CHANGE ORDER
6 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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STRENGTH
IN NUMBERS If your project requires wood forms—massive or small, complex or simple—you won’t find a better company to take it on than UFP Concrete Forming Systems. Our strength is in our numbers: the number and variety of projects managed by our team, the many dedicated account managers and service capabilities we offer from coast to coast, our unlimited access to lumber at the most competitive prices, and the products we develop that keep us on the cutting edge. When you add it all up, you have a reliable partner you can count on for the success of your project.
That’s Value by Design. Any way, shape or form.
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UFP Concrete Forming Systems
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NEW PRODUCTS Dayton Superior B33F High Strength Brace Dayton Superior Corporation, the North American provider of engineered product solutions for the nonresidential concrete construction market, is adding a new high strength brace, the B33F, to its Accubrace brand product portfolio. Dayton Superior’s B33F High Strength Braces are designed for precast and tilt up construction applications such as retail and entertainment venues, educational facilities, as well as mixed use and office buildings. • The all-steel, heavy duty wall braces offer a safe working load of 15,000 lbs. with a 1.5:1 safety facto • The B33F is engineered for unsurpassed speed and efficiency • Can be used to brace on the inside or outside of the wall panel ForConstructionPros.com/12039500
Kingdom Products’ Rosalia Premium Microtopping System
Alliance JXLZ 38 Features Lighter Design Both powerful and light, the new design on the Alliance JXLZ 38 meter hits the scale beneath the legal limits in more markets. • A tight, highly-functional, outrigger footprint maintains all the versatility and articulation expected from a 38 meter • Newly-streamlined lower-profile side panels and high-strength Rotec pedestal design. ForConstructionPros.com/12057143
Kingdom Products’ Rosalia is a highperformance, cementitious, microtopping overlay system designed for interior or exterior applications. Used in conjunction with Kingdom Products Universal Primer Activator and available in three different grades, numerous different effects can be achieved through various application methods using stains, dyes and pigmenting techniques. • Use the Profile Corrector to restore a shot blasted or spalled surface or to provide a standard broom finish • Use the Fine Standard Build and the Super Fine Crema to correct imperfections or to achieve a high-profile glass smooth finish • The Rosalia line is also an ideal base for logos and graphics ForConstructionPros.com/12045586
8 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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Floor grinding just got easier. Introducing the Husqvarna PG 820 RC, our first remote-controlled floor grinder! The PG 820 RC offers very high productivity, powerful performance, and outstanding ergonomics. The remote control is key on this machine. It enables the operator to move around the jobsite, correcting hosing, moving the dust collector, inspecting the floor, and preparing the next set of tools. This leads to increased productivity and less fatigue on the operator. The remote control unit can optimize the grinding parameteres to assure quality for a specific application, enabling consistent operation and results even when changing operators. The PG 820 RC is one of the most powerful and efficient machines on the market. It is an excellent choice for concrete floor preparation and repair, as well as all polishing and grinding applications.
17400 West 119th Street • Olathe, Kansas 66061 • T 800-288-5040 • F 800-825-0028 • www.husqvarnacp.com Copyright © 2015 Husqvarna AB (publ.). All rights reserved. Husqvarna is a registered trademark of Husqvarna AB (publ.).
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Olin Engineering, Inc. has pushed CFA Pile grouting to the max with its latest version of the 5 200CA, the 5 220CA. According to the company, Olin is the most commonly used pump in the CFA or “Auger Cast” Pile Deep Foundation industry. • Powered by a 260 hp Cummins and 250cc of Kawasaki hydraulic pump, it will empty 10 yard loads of structural grout mixes in under three minutes. • The company builds five models exclusively for the application from 75 to 200 yph. • A complete line of stationary concrete, shotcrete and ½” minus aggregate ball valve pumps are available. ForConstructionPros.com/12061229
10 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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The Original Screed Bracket from Kraft Tool Co. Kraft Tool Co. introduces the Original Screed Bracket. Efficiently maximize your movement when spreading and screeding slabs with this new tool. This tool reduces fatigue by covering more surface area with less effort. The innovative design was developed by a contractor to make the most out of each movement while moving concrete. The patent pending design creates a comfortable working angle when pushing or pulling across the concrete. • A finisher can comfortably stand instead of kneeling, thus reducing the stress on the back and knees. • Quickly and easily attaches to screeds or two-by-four boards measuring 1-1/2” thick. • The handles are most effective when used on 4-8 foot screeds. • Requires eight 1” coarse thread drywall screws (not included) to attach the brackets to the screed or board. • Proudly made in the USA. ForConstructionPros.com/12057732
CS Unitec’s EPF 1503 Scarifying Machine PERI Introduces New Slab Formwork GRIDFLEX PERI has introduced GRIDFLEX, a lightweight aluminum grid element system that saves time by eliminating the need to set up and position girders individually. • Requires only four main components – prophead, one standard and two filler elements. • After an area is enclosed, the grid just needs to be covered with any grade of plywood, nailed down to the aluminum struts. • The lightweight design, with a standard element only weighing around 40 lbs., allows a single person to easily handle the system. ForConstructionPros.com/12055112
The new EPF 1503 Scarifying Machine enables contractors to knock off plaster, roughen concrete, level screed or remove old paint. The dust guard is vertically adjustable and connects directly to a standard vacuum hose. The combination of a vertically mounted motor and dust guard extends the life of the tool by keeping dust away from the motor. • The 13.6 AMP motor is powerful enough to scarify large surfaces. • Ergonomically designed to reduce user fatigue. • The EPF 1503 will roughen, descale, abrade, clean and texturize, as well as remove plaster, old paint, adhesives, plastics and resins. • Rated Voltage – 110 Volt • Load speed – 4,000 rpm • Weight: 10 lbs. ForConstructionPros.com/12055573
www.forconstructionpros.com/concrete | April/May 2015 | Concrete Contractor 11
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FLATWORK/ SLAB
By Joe Nasvik
What To Do About DOMINANT JOINTS in Floors A rare case where doing all the right things can make the problem worse.
I
n the best of all worlds there wouldn’t be any joints or cracks in concrete floors at all, they wouldn’t shrink or curl—they would remain flat. Technology is moving us in that direction with the development of shrinkage compensating concrete, shrinkage reducing admixtures, high dosage inclusions of synthetic macro or steel fibers in concrete, and the design of the mixes themselves. Most floors today have contraction joints (previously referred to as control joints) cut into them shortly after finishing operations are complete. Contractors typically measure distance between columns and lay out joints by taking the thickness of the slab and dividing by the number two or two-and-one-half and then adjusting lines for best fit. For example, joints for a six-inch thick slab would be cut every 12 to 15 feet.
Dominant joints can be as much as three-quarters of an inch wide. They are the result of other joints which do not activate or crack. Photo Credit: Joe Nasvik
But joints for slabs with high dosage levels of fibers can be spaced much greater, at column lines or beyond. Joints are usually cut at depths equal to one-quarter of the thickness of the slab (less for early entry saws) with hopes that a crack will form at the bottom of the cut extending to the bottom of the slab, “activating” the joint. If all joints activate, and do not open too much, the width of each crack (and saw cut) remains small enough to allow for aggregate interlock, providing a means for load transfer between one floor panel and the next as forklift traffic passes over. But what if some control joints don’t activate? Cracks at other joints become dominant and wider so that aggregate interlock no longer
exists. In some cases, joint width can become great, causing forklifts to bounce as they pass over, leading to joint edge deterioration and forklift damage. It can also cause trouble for tile floors when they are placed on top.
WHY JOINTS DON’T ACTIVATE? Usually it’s the bad things that cause concrete to have problems, but dominant joints and joints that don’t activate are often the result of constructing floors that represent the best that technology has to offer. Here are some examples.
VAPOR RETARDERS Most floors have vapor retarders placed directly beneath the concrete today and there are many good reasons for this—increasingly the standard as time goes on. But they are also one of the reasons joints
12 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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FLATWORK/ SLAB don’t activate. When concrete rests directly on sub-grade there is a higher coefficient-of-friction between the concrete and the base, resulting in greater stress at joints and causing them to activate. But vapor retarders are also giant “slip-sheets,” making it easier for large slabs to shrink towards their center without activating all control joints. In this case, it’s often the construction joints surrounding the slab that become dominant with widths that can approach three-quarters of an inch.
HIGH DOSAGE LEVELS OF FIBERS Including high dosage levels of fibers is becoming more popular because concrete develops higher post-cracking flexural strength and there is greater resistance to visible cracking. For owners, floor maintenance problems usually start at joints—high fiber floors make it possible to eliminate as much as 70 percent of the joints in floors compared to standard designs. They also reduce the amount of curling in floor panels, reducing the amount of rocking that occurs when forklifts pass over. But they don’t reduce linear shrinkage (fulldepth shrinkage as compared to differential shrinkage, which manifests itself as curling) very much and it’s more difficult for joints to activate. Shrinkage then occurs mostly at construction joints, which can become wide, especially when combined with vapor retarders.
Dominant joints can be as much as threequarters of an inch wide. They are the result of other joints which do not activate or crack. Photo Credit: Joe Nasvik
CURLING
RESTRAINT
When there is very little curling present in floor panels—a very desirable condition—there is less vertical stress on control joints when heavy traffic crosses them and less force to activate joints.
We engineer floor mixes to shrink less and perform better. Floors are stronger and more robust as a result. On the other hand, concrete mixes that aren’t proportioned well or have too much water added result in low compressive strengths. Slabs crack more easily so control joints activate more easily too.
Jerry Holland, Director of Design Services for Structural Services Inc. (SSI), Waxahachie, Texas, says building details and conditions such as the location and isolation of columns and other slab penetrations, walls tied to slabs, dock walls—anything that restrains floor movement can cause some joints not to activate and others to activate more. If a project specifies light steel reinforcement, extending it through control joints causes them not to activate as much as they otherwise would. Heavier than necessary steel reinforcement will not allow them to activate at all, increasing the propensity for cracks and dominant joints.
FINISHING
SOLUTIONS
Today it’s common practice to finish floors with “ride-on” trowels that can weigh 2,000-pounds or more, producing highly densified surface finishes in the range of oneeighth inch thicknesses. They press out pore structures and voids making them very impermeable and abrasion resistant.
The solution to the problem of having dominant joints is to focus on the joints that don’t activate. Joe Neuber, President of Neuber Concrete, Kimberton, Pennsylvania, says he once developed a vibratory roller which they rolled over control joints right after they were sawed in order to activate them. “I think we were somewhat successful,” he says. “But some joints we vibrated didn’t activate so we need to experiment more with our idea.” Unless you are a contractor with expertise in the design of floors it’s best for owners to involve consultants, with local knowledge of materials, who specialize in floor design to specify details such as joint layout and other internal and external restraint issues. If wider construction joints are anticipated, armored edges can be a solution to reduce edge wear and provide a smoother ride for forklifts. If there is no significant curl in
MIX DESIGN
EXTERNAL AND INTERNAL Modern finishing machines can weigh as much as 3,000 lbs., allowing finishers to easily create densified surfaces of 1/8-inch. This is enough to prevent water-of-convenience from escaping, resulting in stronger concrete that can resist shrinkage forces that would activate contraction joints. Photo Credit: Joe Nasvik
14 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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FLATWORK/ SLAB slabs at the edges then the floor plates are supported by the subgrade—provided the sub-grade is properly installed. That being the case, control joints can be cut deeper to further weaken them so they are more likely to activate— aggregate interlock becomes less an issue. Good mix designs which include high-dosage levels of fibers
can produce floors without significant curling, so this becomes an option. The amount that concrete shrinks can be controlled to some extent by the design of the concrete mix. Some contractors who specialize in floor construction have experience in designing their own mixes, Neuber is one of those. He always specifies his own mixes. He says it’s important to place
Concrete Solutions
Free applications guide shows how to boost your productivity If you’ve never used highpressure water jetting, you’ll be amazed at what it can do — and how quickly. NLB’s free PDF applications guide has a variety of examples, with links to videos that let you see for yourself how productive water jetting can be.
Download it today by scanning the QR code, or visit www.nlbcorp.com/applications/concrete/. Then call your NLB regional branch (below) for a demo, and put water jetting to work for you.
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Most floor slabs require vapor retarders under them now. They prevent ground moisture from moving through the slab, but they also act as a slip-sheet allowing large floor areas to contract without activating joints. Photo Credit: Joe Nasvik
well-graded mixes—optimizing the aggregate distribution to minimize void spaces and the amount of cement paste needed for the concrete. “We think the key to a good mix is to start by including 1½-inch top sized aggregate,” he says. His designs produce concrete with four-inch slumps—less than ideal for placement so he includes mid-range water reducers to achieve the right placing slumps. But contractors like Neuber, who have the knowledge to design their own mixes, are rare so it’s best to involve consultants on projects who can supply the needed expertise. Bryan Birdwell, Senior Floor and Pavement Consultant for SSI, is one who is experienced both as a large flooring contractor and now as a consultant. He understands the issues from both sides. He says managing the amount of shrinkage is very important and that’s something consultants can help contractors with. “Restraint is a primary reason that dominant joints occur also. Inadvertently they get designed into a floor,” he adds. Using shrinkage reducing admixtures (SRA’s) is another way to help to control shrinkage. BASF recently introduced an admixture called “Master Life CRA007” and it is based on all new technology. It reduces shrinkage, the potential for cracking, and crack
16 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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FLATWORK/ SLAB The industry understands more about designing concrete floor mixes now— seen as a good thing. But stronger and better performing concrete can also be a reason that joints don’t activate.
width. But greatly reducing shrinkage doesn’t activate more joints, it helps to reduce slab movement and control the width of dominant joints. Linear shrinkage and curling are closely related—controlling shrinkage tends to control curling. But the reverse isn’t true; slabs can experience normal levels of shrinkage without appreciable curling. The introduction of high dosage levels of fibers in concrete is one way to achieve this. Finishing slabs with heavy troweling machines to create densified surface layers of approximately one-eighth inch thicknesses is another. The densified layer acts as a vapor retarder that prevents moisture of convenience from leaving the slab, especially when there is a vapor retarder underneath it. So concrete builds strength long before the slab dries out—a process that can take years—resisting curling and shrinkage forces as a result.
Photo Credit: Joe Nasvik
Dan Biddle, Vice President of Sales for the FORTA Corporation, Grove City, Pennsylvania, confirms that high dosage levels of synthetic macro fibers in the range of seven-and-a-half pounds per cubic yard of concrete (0.5 percent by volume), can cause some joints not to activate. As per ACI, contractors should cut control-joints onethird the thickness of a slab to encourage joint activation for higher fiber dosages such as this. Since curling is very minimal, any loss of aggregate interlock isn’t a big issue. There is difference of opinion
about how joints should be spaced in floors, regardless of concrete ingredients. Some reason that the closer control-joints are spaced, the less worry there is about joints not activating. However, building owners tend to think that fewer joints mean lower maintenance costs down the line, so they want their floors to have the least number of joints (and cracks) possible.
WHERE TO NOW? If you are reading this article looking for answers you’ll notice there are few offered, dominant joints are a concern with few answers at this point in time. Neuber, as the chairman of the ACI 302 Floor Construction committee says this is a future agenda item for the committee.
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18 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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FOUNDATION/ WALLS
By Mitch Bloomquist
Acceptance of Tilt-Up Concrete Continues to
O
ver the past 10-plus years, much has been published regarding the capacity of tilt-up to deliver multistory, irregularly shaped, complex projects. The Tilt-Up Concrete Association’s Annual Tilt-Up Achievement Awards Program has evidenced the ever increasing variety of project types, forms and sizes that have since become commonplace. The reputation of tilt-up as solely a way to construct plain big boxes has begun to fade and tilt-up is now regularly considered for almost every project type, depending on the region. “From warehouses and functional origins, tilt wall has begun to transverse building types at an amazing rate,” writes Jeffrey Brown of Powers Brown Architecture. “While there is still much work to do regarding the seriousness with which architects and academia take the method as an innovative way of form making, tilt-up has come a long way.” Still, among all of these efforts and the success tilt-up has had expanding into new markets, it is important to acknowledge and discuss the relevance and dominance tilt-up enjoys when it comes to the construction of the building type known within the industry as the rigid wall, flexible diaphragm, large box structure. “There is simply no way to beat tilt-up when constructing a building of this nature,” says Mike Wolstenholme, National Tilt-Up Sales Manager for Meadow Burke. “It remains the most cost-effective, time-sensitive and efficient way to construct a warehouse box and,
therefore, it remains the bread and butter of our industry.” Although “simple” is often used to describe these structures, many times the projects are far from simple either in structure, configuration or site adaptation. The moniker “simple”, however, is used to refer to the relationship of the perimeter wall envelope supporting an expansive roof with few juxtapositions or features that present challenges to engineering.
PERFECTING THE BOX “Are we getting better at the simple buildings? Yes,” says Laurence Smith, P.Eng., Vice President of Engineering with Lindsay Construction in Dartmouth, Nova Scotia, Canada, “and the improvements exist across the entire process. From the time before the building is designed to the setting of the last panel, the process continues to get better.”
RISE
The penetration of tilt-up into new markets continues to improve efficiencies. Advancements in lifiting and bracing technology have also fueled greater efficiency. Photo Credit: Tilt-Up Concrete Association
One factor contributing to increased efficiencies in some markets, according to Smith, is their maturation. Eight to ten years ago, Smith had to sell the concept of tilt-up to clients. Now they come wanting it from the beginning. Even so, as early as five years ago Smith says clients would come with a building designed in another system that required conversion to tilt-up in order to deliver the advantages they desired. “The process of converting these projects, while worth it, took so much energy and time,” said Smith. “In mature markets, much of this is gone.” Smith explained that new markets can present challenges in the field
20 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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Southwest Products built a new state-of-the-art facility at its Surprise, Arizona location. The facility will increase production efficiencies to satisfy U.S. and world demand. Photo Credit: Tilt-Up Concrete Association
as well. “With the oil industry boom in Canada, companies were bringing in these large cranes to regions that before had no access to the machinery needed to lift large panels efficiently,” says Smith. Because of this, Lindsay Construction was able to expand and bring tilt-up to markets unfamiliar with the building system. Smith explained that at home there were one or two cranes and one or two crane operators and for them lifting panels was second nature. As Smith visited jobsites in this new region and asked those who had never seen anything like this to raise their hand, he was only slightly surprised to find that he was one of the only ones with his hand down. “It’s exciting and extremely gratifying to introduce something completely new,” said Smith, “but it obviously comes with some complexity. I tell them, take the first one slow. They listen. Then I say, let’s do another.” This penetration of tilt-up into new markets continues to improve efficiencies as more clients and contractors become familiar with the method. Contractors in Florida, Texas, and California haven’t encountered these issues for years. However, in these markets, advancements in lifting and bracing technology have fueled greater efficiency where according to Wolstenholme, “large, simple boxes are coming back in a huge way.”
“Although we’ve done a large number of Class-A office buildings in tilt-up with fantastic results, the economy and speed that tilt-up brings to warehouse type construction is unmatched,” says Chip Dehart, an Estimator for Suntec Concrete, Inc., one of the largest commercial concrete construction companies in the Southwest. “We can put up a 400,000 square-foot warehouse (footings, slabs, and panels erected) in six weeks or less.” Dan Dancer, Product Line Manager for Dayton Superior, an industry leader in the design, manufacturing and distribution of specialized concrete construction products, says, “By in large, the majority of our work for the tilt-up industry comes from single-story tilt-up projects.” For that reason, they and other industry manufactures continue to develop simpler, faster and therefore more economical ways of forming, lifting and bracing tilt-up panels.
“Meadow Burke has an extremely fast, safe and strong lift system called Super Lift III,” says Wolstenholme. “It allows for panels to be erected at a fast rate, especially in the repetitive process.” Wolstenholme explained that engineers work to keep rigging changes to a minimum during lifting and bracing engineering, which facilitates faster erection times. Methods of securing the braces to the slab also continue to improve. “We have developed strong, safe and fast brace-anchoring systems such as the Slam Anchor and the MB Brace Bolt,” says Wolstenholme. “The system allows for quick attachment of the braces to the floor while meeting the strict brace loads required.” Even the average height of the panels has changed in the simple big box as developers have required greater interior clear heights for their tenants. The taller the panel, the greater the force on the floor slab during the bracing period, and this can be a real challenge. Additionally, bracing to the outside of the building is becoming a more and more common practice. Initially developed primarily for multistory projects and/or projects with a relatively small footprint, these larger “simple” projects can have issues related to the preservation of the slab (no holes) and the facilitation Retailer, American Furniture chose to build a new warehouse using the tiltup method of construction. Photo Credit: Tilt-Up Concrete Association
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FOUNDATION/ WALLS of quicker, more efficient steel erection. The experience in bracing to the outside from the newer markets has made this strategy a good option. Manufacturers continue to refine lifting and bracing systems, making them more efficient and versatile. Today, helical ground anchoring systems have become the primary method used to brace panels to the outside, significantly speeding up the process and applying greater safety around the perimeter where large blocks of concrete, called “deadmen”, used to be found.
KEEPING IT SIMPLE AND TURNING A PROFIT In addition to being the building type that brings out the very best of tilt-up’s efficiencies, many contractors would agree that these projects are also the most profitable. Clay Fischer, CEO at Woodland Construction Company, Inc. once
Rapid Set
®
proclaimed, “If we won an award for the project, we probably didn’t make much money on it.” Many have shared this opinion as they jokingly describe the complexity and unforeseen challenges many times found in projects that the judges often react to most favorably. It also implicates that projects many consider mundane are the ones where contractors can produce the best results for their profitability. According to Smith, “It’s not the size of the project that is necessarily the determining factor for efficiency or profitability. I can look at a basic project (without high-end finishes) under construction, and based on the simplicity of the bracing scheme, give you a ball-park square foot cost,” Smith explains. “The two are directly related in my experience.” No matter the size of the box, what Smith refers to is the relative simplicity to which the big box building type is known.
Panels are routine or repetitive in their size, bracing schemes and lifting layouts are not altered significantly, and openings are repetitive. They account for as basic an approach to both cost estimating and construction as possible in any industry, but especially so for tilt-up. When asked about the best size for tilt-up projects with this idea in mind, Smith, a past president of the Tilt-Up Concrete Association,
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22 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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Methods of securing the braces to the slab also continue to improve. Manufacturers have developed strong, safe and fast brace anchoring systems. Photo Credit: Tilt-Up Concrete Association
PROJECTING THE FUTURE
explained that everything goes full circle. “With regards to the feasibility of a tilt-up project and its economies related to size, a 20,000 square-foot project was once considered the minimum,” says Smith. “Then it went down to 15,000 square feet, then 10,000 square feet. We have done 5,000 square-foot projects very economically and the clients are happy.” For Smith, it is all about the simplicity and efficiency of the design.
While there is no science behind the prediction of what the future holds for the industry, one thing is clear: the economy has rolled around to the return of this big box. Companies like Amazon, Wal-Mart and many more are once again committing to massive projects with a basic perimeter envelope and acres of roof area. This has the tilt-up construction industry poised to display the effectiveness and the efficiency that became the calling card for many contractors during the 90’s and early part of this millennium. The past is still not the future, however, and today’s new big box projects have implemented many
design changes that are introducing new challenges to construction professionals. New requirements for energy performance and air barrier construction are ushering in a new era of insulated wall technology to a building category that had been largely exempt from the control of energy consumption. “While we are always evolving,” says Smith. “That one market will never go away. When that building comes along, and tilt-up is an option, it will always be the best solution.” Tilt-up’s position among other methods of constructing relatively large low-rise hard-walled structures is rarely challenged. While tilt-up is being employed as a project solution for an ever-increasing variety of building types, these projects continue to exploit some of the most valuable of the building system’s advantages, and they are only getting better.
www.forconstructionpros.com/concrete | April/May 2015 | Concrete Contractor 23
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CONCRETE BUSINESS
By Elizabeth K. Schneckenburger
Concrete Foundations Association Introduces Industry Specific Insurance Program What it means for the concrete contractor.
O
n February 2nd, 2015, Concrete Foundations Association (CFA) Executive Director, Jim Baty, announced Arthur J. Gallagher as the appointed broker for the newly formed CFA Insurance Program. Arthur J. Gallagher, the fourth largest insurance broker in the world, maintains two of the leading construction and captive practices in the industry. CFA board members realized that one recurring issue for all members was that the costs associated with risk management was one of the top five expenses annually. Members’ bottom-line profits weigh heavily on the success of managing all elements of their Total Cost of Risk (TCOR) such as: premium, claims, safety, EMR, and contracts. Several years ago, CFA board members had the foresight to explore risk management options for members. They wanted to be able to give their members more—more opportunities to network, more platforms to share ideas with one another, more data on safety, more guidance on contractual risk and more options to address problematic issues relating to the daily operations of a construction company. The Gallagher/CFA cultures sync well and create a natural partnership for the implementation of the insurance program. This foundation will offer a viable and competitive alternative to the industry standard
insurance placements for all CFA members that participate in the Program and allow them to adequately manage their Total Cost of Risk (TCOR). The construction insurance market is ready for a fresh start. For so many years the industry handicapped companies from capitalizing and historically provided cyclical pricing. TCOR takes into consideration all aspects of your business’ risk management program; Experience Modification Ratings, safety controls, establishing proven contract standards, effective return to work programs, the legal cost associated with contracts and claims, certificates of insurance, time management of an insurance program, training employees, contract reviews, and sub-contractor management. Impacting these cost drivers will help to make your company more cost effective, drive down total costs and over time, bear fruit and impact your pure premium. The goal of the Insurance Program is to provide CFA members with the ability to standardize processes for claims, safety, coverage, contract management, and certificate of insurances. By focusing on the whole picture, this program will be better positioned to impact cost drivers than a run of the mill, off the shelf approach year in and year out. In order to align the CFA Insurance Program right from the start the program will address TCOR head on. Kristen Long, Arthur J. Gallagher’s Midwest Regional
Practice Leader will spearhead the action plan for the reduction in Total Cost of Risk which will focus on these three areas: Financial Discipline, Consolidation, and CFA member Growth Strategies. • Financial Discipline - Managing the costs associated with risk is a critical step toward developing an optimal risk management program. A member of the Program can expect to see a decrease in internal costs as we increase purchasing leverage to reduce insurance costs, implement heightened risk management training, standardize procedures specific to the concrete foundation industry, enhance coverages, and provide coaching on indemnification agreements. The long-term goal of the CFA Program will stabilize members’ Total Cost of Risk. • Consolidation – Analytics will allow the Program to benchmark information relating to injury types, frequency, severity, experience modifications, return to work costs, legal expense and PPO network saturation.
24 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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This will eliminate redundancies and streamline the process. Combining data stored from three different sources will provide insight for program members not available in the standard market and provide insurance program members an advantage in the marketplace against competitors. • Growth Strategies – Helping member’s grow their individual companies is valuable. Risk management plays a large role in a company’s success and ability to grow profitably. The CFA Insurance Program must provide its membership with that flexibility. Our job is to assist your individual companies grow profitably and healthy by having an adaptive insurance program that plans for every uncertainty and to ensure nothing will stand in the way of growing each member’s business and the CFA
Insurance Program. Providing surety, coverage that matches contracts, emerging risks, safety, and regulation all play a key role. “The CFA Insurance Program with Gallagher is what we have been striving to achieve for several years,” says Ed Sauter, Steering Committee Member. “This will give our participating members the opportunity to have an impact on the future of the industry and their own insurance rates. Gallagher has the experience and clout in the industry to give us the program we want and need.” The CFA Insurance Program is the first step. Together, with the support of the CFA membership, the CFA is creating an industry specific program that is establishing a platform where all members can collaboratively share best practices and effectively impact a CFA member’s TCOR. Liz Schneckenburger of Arthur J. Gallagher has triggered the beginning phases of establishing
the program by taking a 20 percent sample of the CFA membership as the initial members. “The members of the association wanted “smart options”; options that could not only protect their businesses but also have the potential to impact their bottom line,” says Schneckenburger. “CFA members are excited about the opportunity Gallagher is bringing to the table. Just like any table that needs to be set before being served, we are in the process of polishing the data and setting up the program.” The final program design will be presented at the annual CFA meeting on July 22nd. Both Long and Schneckenburger will be attending the meeting. Ed. Note: Elizabeth Schneckenburger is an account executive with Arthur J. Gallagher & Co. She can be reached at Liz_Schneckenburger@ajg.com.
DELIVERING SUSTAINABLE SOLUTIONS After water, concrete is one of the most sustainable and widely-used materials in the world. Fly ash plays an important role in increasing the sustainability of concrete. Headwaters Resources is the nation’s leader in supplying quality fly ash. We can help you discover how to improve the performance of your concrete while simultaneously improving its environmental profile. Visit www.flyash.com for answers to the most common questions about fly ash. You can also contact your expert Headwaters Resources technical support representative for advice on your specific sustainability opportunities.
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www.forconstructionpros.com/concrete | April/May 2015 | Concrete Contractor 25
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SPECIFICATION GUIDE: SCREEDS
Screeds
A compilation of technical information when choosing your next screed. Hand and Spin Screeds
1 The EZ Screed Complete Tool Set
The EZ Screed Tool is designed for walks, driveways and slabs of various sizes. The EZ Screed Tool used in an upright position is faster and more effective in the leveling of concrete, resulting in a more precise, professional finish to your concrete job while minimizing stress on back and knees as in the traditional method of screeding. Features: Powder coated handle with stand, quality aluminum blades (3 to 7 lbs. each), lightweight and durable. ForConstructionPros.com/10080016 Model
Weight (lbs.)
Blade Lengths
Handles
EZ Screed Complete Set
5 lbs. per handle, 1 lb. per foot for aluminum screeds
3’, 4’, 5’ and 7’ aluminum screeds
Powder coated steel handle
Model
Weight (lbs.)
Blade Lengths
Handles
5 lbs. per handle
Will attach to any 10’ to 20’ aluminum or wood screed
Powder coated steel handles
EZ Screed Pro Two
2 EZYSCREED with Inbuilt Level
EZYSCREED is a manual screed, featuring an inbuilt level and reversible capabilites. It is lightweight with a designed screeding edge and reinforcements, making it the most useful, economical and strongest screed on the market. Available in lengths from 0.9 m / 2’11” to 3.6 m / 11’9”. ForConstructionPros.com/12003790 Model
Weight (lbs.)
Blade Lengths
Handles
EZYSCREED
Multiple weights
Multiple
1
3 Spin Screed Rugged Screed
The Spin Screed was designed and built by an experienced concrete contractor. The Spin Screed has been field tested for over 12 years and is built with the highest quality components. It will begin to make money for your construction business as soon as you place it in service. You won’t be disappointed with the Spin Screed - it will improve your bottom line and make your employee’s job easier. ForConstructionPros.com/10084911 Model
Weight (lbs.)
Blade Lengths
Handles
Spin Screed Rugged Screed
82 lbs. with 22’ of pipe
Varies depending on length of pipe attached
2 - one on each end of the pipe
26 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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SPECIFICATION GUIDE: SCREEDS
Wet Screeds
Pneumatic LBG 800 Bull Float 1 Chicago and LBG 1200 Screeds Chicago Pneumatic offers two new walk-behind screeds—the LBG 800 bull float screed and LBG 1200 hand-held screed (pictured)—that are light and easy to handle. They are designed to provide a consistent, even surface without any guide or supporting tube. Equipped with a Honda engine, the screed features a rubber element to reduce hand arm vibrations. For quick adjustments, the ignition switch and throttle control are within easy reach for the operator. ForConstructionPros.com/12057796 Model
Weight (lbs.)
Engine/Motor Manufacturer
Engine/Motor (horsepower)
Displacement
Blade Lengths
Handles
Tank Capacity
CP LBG 800 Bull Float Screed
40 lbs.
Honda GX25 Mini 4-Stroke Engine
1.1 hp
25 cm4
84 in.
Three snaplock sections, extending up to 180 in.
.61 U.S. qt. / (0.58 Liters)
Model
Weight (lbs.)
Engine/Motor Manufacturer
Engine/Motor (horsepower)
Displacement
Blade Lengths
Handles
Tank Capacity
CP LBG 1200 Hand-Held Screed
6 lbs., up to 26 lbs. (six models available)
Honda GX35 4-Stroke Engine
1.3 hp
35.8 cm3
48”, 72” 96” 120”, Two adjustable 144” handles 168”, 192”
.67 U.S. qt./ (.63 Liters)
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28 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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2 Allen HD7070 Magic Screed
According to the company, the Allen Magic Screed was the first floating/ wet screed on the market and is the #1 selling screed in the world. It is light and has enough blade surface area to allow it to float in wet concrete. The adjustable handles and lifting bar make it extremely user friendly. In addition to the gas powered screed, an electric unit with a rechargeable battery is available for use in non-ventilated areas. ForConstructionPros.com/12057778 Model
Weight (lbs.)
Engine/Motor Manufacturer
Engine/Motor (horsepower)
Displacement
Blade Lengths
Handles
Tank Capacity
Allen HD7070 Magic Screed
36 lbs.
Honda GX35
2.5 hp
35 cc
4’ to 16’ in 2’ increments
Dual handle height adjustable
.63 Liters
3 MBW SCREEDEMON
From a health and safety viewpoint, the SCREEDEMON lowers wet screed hand/arm vibration by between 50 and 90 percent. Hand/arm vibration is linked to a number of occupational health problems including white finger, carpel tunnel syndrome, and chronic arthritis. the link between engine and eccentric is a low cost, very durable, flex coupler. High maintenance flex-cables or rigid shafting is eliminated. the SCREEDEMON couples to its screed bar via a compression lock. The magnesium screed bar is designed to work within the natural frequency of the screed/bar combination. The back-to-back double triangular design is very rigid and offers comparatively uniform vibration along the full length of the bar. ForConstructionPros.com/10083973 Model
Weight (lbs.)
Engine/Motor Manufacturer
Engine/Motor (horsepower)
Displacement
Blade Lengths
Handles
Tank Capacity
ScreeDemon WS500H
29 lbs. (power unit only)
Honda
GX35
1.9 in3
4 ft. up to 24 ft.
N/A
0.17 gal.
www.forconstructionpros.com/concrete | April/May 2015 | Concrete Contractor
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Clear Industrial Epoxy or Custom Tinted Epoxy provide an extra layer of protection for a concrete floor to endure constant wear and tear. In addition to its protective function, a coating can also dress up a drab surface, simplify maintenance and improve skid resistance.
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SPECIFICATION GUIDE: SCREEDS Wet Screeds Continued
Neuson Wet Screed Now Available 4 Wacker with Magnesium Boards Wacker Neuson’s wet screed is now available with a full line of magnesium boards. Magnesium is a strong, lightweight metal that will reduce the weight of the boards by over 25 percent compared to aluminum boards. The full line of magnesium boards is available in seven different lengths: 6-, 8-, 10-, 12-, 14-, 16-feet and a 2-meter option. All the magnesium boards have a 4.9-inch width and range in weight from 9.8-pounds to 25-pounds. The boards are easily connected to the wet screed system. ForConstructionPros.com/12058112 Model
Weight (lbs.)
Engine/Motor Manufacturer
Engine/Motor (horsepower)
Displacement
Blade Lengths
Handles
Tank Capacity
P35A Wet Screed
36 lbs.
Honda
1.6 hp
2.2
4 ft. to 16 ft.
Twin/low vibration
0.6 qts,
Power Screeds
1 Ligchine International ScreedSaver II
The ScreedSaver II brings you the best of all worlds. It’s compact, yet so very powerful. It has independent proportional front wheel drive resulting in zero turn capability. This is the world’s first wireless remote controlled laser leveling screed machine. Features include: Automatic Laser Leveling,a Labor eliminating Auger head measuring 10.5’ (3.2m), boom extension of 12.5’ (3.8m), resulting in screed rates of 3,000 sq. ft/hour (278m²). ForConstructionPros.com/10767948
Model
Height (inches)
Width (inches)
Weight (lbs.)
Boom Reach
Engine/Motor (Mfg & Horsepower
# of Drive Wheels
# of Steer Wheels
Tank Capacity
ScreedSaver II
54”
54”
2,682 lbs.
12’6”
Honda 20 hp/ Gasoline
2 Drive/Steer wheels/2 free spinning
N/A
5 gal. gasoline / 20 gal. hydraulic
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32 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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Power Screeds Continued Model
Height (inches)
Width (inches)
Weight (lbs.)
Boom Reach
Engine/Motor (Mfg & Horsepower
# of Drive Wheels
# of Steer Wheels
Tank Capacity
N/A
5 gal. diesel/ 20 gal. hydraulic
2 Drive/Steer Kubota 35 hp All-Terrain Tracks Diesel and 2 free spinning wheels
ScreedSaver XT
66”
65”
3,832 lbs.
12’ 6”
Model
Height (inches)
Width (inches)
Weight (lbs.)
Boom Reach
Engine/Motor (Mfg & Horsepower
# of Drive Wheels
# of Steer Wheels
Tank Capacity
Screedsaver Max
62”
79”
4,260 lbs.
16’
Kubota 35 hp Diesel
2
2
5 gal. diesel / 20 gal. hydraulic
2 Somero 15R Laser Screed
The Somero 15R Laser Screed features dual proportional hydraulic cylinders over the head adjust to grade 10 times per second. A selfleveling head matches the pitch of the slab 10 times per second. Other features include: Automatic soft landing control, automatic column block protection, LCD display screen, 360-degree hydraulic frame rotation, 3D Profiler System available, plug-n-play ready. ForConstructionPros.com/12058136
Model
Height (inches)
Width (inches)
Weight (lbs.)
Boom Reach
Engine/Motor (Mfg & Horsepower
# of Drive Wheels
# of Steer Wheels
Tank Capacity
S-15R Laser Screed
6” 4”
6’ 7”
8,796 lbs.
20 ft.
Kubota 35 hp Tier 4i
4 wheel drive
2 wheel/4wheel/crab steer modes
12 gal.
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www.forconstructionpros.com/concrete | April/May 2015 | Concrete Contractor
CONC0415_26-35_SpecGuides.indd 33
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SPECIFICATION GUIDE: SCREEDS Power Screeds Continued Model
Height (inches)
Width (inches)
Weight (lbs.)
Boom Reach
Engine/Motor (Mfg & Horsepower
# of Drive Wheels
# of Steer Wheels
Tank Capacity
S-22 Laser Screed
8’ 1”
7’ 2”
8,796 lbs.
20 ft.
Duetz 74 hp, Tier 4i plus auxillary power unit
4 wheel drive
2 wheel/4 wheel/ crab steer modes
12 gal.
Model
Height (inches)
Width (inches)
Weight (lbs.)
Boom Reach
Engine/Motor (Mfg & Horsepower
# of Drive Wheels
# of Steer Wheels
Tank Capacity
S-485 Laser Screed
4’
3’-7-1/2”
1,107 lbs.
Unlimited, no boom
Honda 20.8 hp
4 wheel drive
4 wheel steer
4.25 gal.
Truss Screeds
1 Allen SE12 Steel Truss Engine Driven Screed
Allen truss screeds have been the standard of the industry for 40 years. FL (floor levelness value) is enhanced with these machines on industrial floors slabs. Accessories include a bridge deck handle that allow the screed to be used on a wide variety of bridge deck applications. The Allen field staff is available to assist with any screed application. ForConstructionPros.com/12057760
Model
Height (inches)
Width (inches)
Weight (lbs.)
Boom Reach
Engine/Motor (Mfg & Horsepower
Tank Capacity
Allen SE12 Steel Truss Engine Driven Screed
16-3/4”
17-1/2”
18 lbs. per LF
N/A
Honda, 9 hp, gas
5.3 Liters
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34 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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Truss Screeds Continued Model
Height (inches)
Width (inches)
Weight (lbs.)
Boom Reach
Engine/Motor (Mfg & Horsepower
Tank Capacity
Allen SA12 Steel Truss Air Screed
16-3/4”
17-1/2”
18 lbs. per LF
N/A
Air operated piston vibrators
N/A
2 MBW Blitzscreed
The MBW Blitzscreed is a lightweight aluminum screed designed for flat, inverted or crowned applications up to 65 ft. Available section lengths include 8 ft. 4 in., 4 ft. 4 in. and 2 ft. 4 in. The diagonal truss/ A-frame system offers structural strength while the flex-couplings and turnbuckle design makes for quick assembly and disassembly. Blind nuts help keep concrete off threads and eases disassembly/assembly. Hydraulic winches are also available. ForConstructionPros.com/12057874 Model
Height (inches)
Width (inches)
Weight (lbs.)
Boom Reach
Engine/Motor (Mfg & Horsepower
Tank Capacity
MVS Mechanical Blitzscreed
16”
15”
8.3 lbs./ft.
N/A
Up to Honda GX270 (8.5 hp)
5.6 Qts.
Model
Height (inches)
Width (inches)
Weight (lbs.)
Boom Reach
Engine/Motor (Mfg & Horsepower
Tank Capacity
AVS Air Blitzscreed
16”
15”
8.9 lbs./ft.
N/A
N/A
N/A
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www.forconstructionpros.com/concrete | April/May 2015 | Concrete Contractor
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DECORATIVE CONCRETE
By Bart Sacco
Micro-Toppings Offer A Wide Array of Decorative Finishes The versatility of concrete micro-toppings offer contractors options to create various effects with few limitations.
M
icro-toppings and engineered cements serve many purposes in our industry today. Most people walk on them everyday and don’t even know it. Micro-toppings and engineered cements are different from standard concrete in a lot of ways. These specialized coatings exhibit unique properties that make them incomparable to a standard concrete surface. It’s not just a mix of sand and cement like your grandpa used to make. Many of these coatings are applied in multiple, paper thin layers that when completed only amount to the thickness of a standard credit card. There are also high-strength, non-shrink mixes that can be applied up to six inches thick or more. Properties such as adhesion, abrasion-resistance, shrinkage-resistance, workability and open working time are also things to consider. Many of these coatings exhibit very fast set times, allowing the possibility to quickly return the structure back to service. The application, final texture and desired look will also be determining factors in the selection of the proper coating needed for the job. For these specialized coatings to perform in the manner for which they were intended, it takes a complex mix of minerals and ingredients. Dry versions contain specialized, dry, dispersible, high-performance admixtures blended within the powder. Liquid versions are a two component product with the chemicals in liquid suspension.
There are many products designed to resurface any type of defective slab or weathered surface a professional contractor may encounter. There is not a “one size fits all” material on the market today. The products that claim to do everything will either lack the gradation to achieve a degree of fineness typical of a true micro-topping or will lack performance when spread too thin. Also, some are not suited for harsh freeze-thaw environments and therefore only suitable for interior use. There are differences between products, including the flexibility they offer and the thickness they can be applied at in one lift. Application methods differ as well, so there are many things to consider. Do as much research as you can before proceeding. I am always being asked, “What product should I use”? The first thing I
Pictured here is a substrate that was scrubbed with a silicon carbide impregnated nylon grit brush and given two coats of micro-topping to restore the floor. Once the waterbased dye was applied, the old details of the vinyl tiles appeared. Photo Credit: Kingdom Products
always recommend is go to the jobsite; see what you’re actually up against and discuss the desired repairs with the customer. Without physically seeing the condition of the substrate it will be impossible to determine the amount of labor or materials it will take to do the job properly. It may be an interior job that requires a coating over a wood substrate or an exterior slab that is spalled due to winter damage. You will also need to know for sure if the substrate was sealed or coated previously and with what. If you are resurfacing,
36 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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all coatings will need to be removed for proper, long term adhesion.
UNDERSTAND THE PROCESS It is equally important to understand the steps needed for a successful micro-topping or concrete resurfacing project. While most slabs will be good candidates for toppings, some surfaces may need special preparation work and others a complete replacement may be the most suitable and best option. The condition of the surface will determine if the cost of repair will exceed the cost of removal and replacement. It is also important to understand how crucial proper surface preparation is to a successful long-term coating installation. If the surface is in an exterior setting and heavily spalled, all loose debris will need to be removed and the surface must be taken down to solid concrete. This usually means it will take numerous individual coatings of a micro-toppings or engineered cement to bring the low lying areas of the slab back up to a flush and uniform end result. The multiple coats must be accounted for upfront and figured in to the overall cost of
the project, because they mean both labor and materials. Another option would be to diamond grind the slab flush and then apply the toppings. You will use less material but you will still eat up labor and diamonds in the prep process, adding expense. Now let’s take another exterior slab that is in very good condition with no spalling, cracks or sealer to remove. This type of slab would simply need a good pressure washing to remove mold, dust, and any surface contaminants, but DO NOT SKIP the very necessary mechanical agitation, needed to dislodge the dirt and debris clogging the pores of the surface. A 175 rpm floor machine fitted with a nylon brush in conjunction with cleaning agents works wonders. Then immediately pressure wash the surface before any of the debris or cleaner have time to dry. It is very important to not allow the debris created during scrubbing to dry to the surface. Continue this process until the rinse water is running clear. After the excess surface water has evaporated the slab will be ready to coat. There is a world of difference in the labor costs between these two
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WHAT ARE THE BENEFITS OF MICRO-TOPPINGS? Micro-toppings might be one of the easiest to use and most diverse materials for concrete contractors. According to Tim Frazier, Lead Trainer/Research and Development at The Stamp Store, if you’re looking for a product to provide extraordinary adhesive properties, you should be using them. Micro-toppings are a one or two component cementious coating which includes a polymer and some Portland cement and sand. “Normally, on a concrete slab, your high-abrasion resistance is about 4,000 to 6,000 psi; so you can literally mechanically profile and chemically adhere the topping to any surface,” he says. The contractor may also add filament tape in the mix to create patterns on the slab without using stamps. Using hand textures, slop trowels or a smooth finish may add greater depth and dimension to the surface where the micro-topping is being applied. In the case of a residential or commercial space, a micro-topping can be hard troweled for a power trowel finish. For exterior applications, Frazier says it can be more complicated because of other factors not present in interior applications. “Because of the moisture contents on the slab, slip resistance may be a factor. If you apply a power trowel finish on the slab then you’re relying on an anti-slip additive in a coating or sealer. However, you can achieve the same slip coat by putting in a stipple effect or a knock down, like a hopper gun application, to add to the surface tension. Whenever your foot hits the surface, you’re making contact with multiple surfaces, giving you more friction and allowing for better traction when walking.”
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www.forconstructionpros.com/concrete | April/May 2015 | Concrete Contractor 37
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DECORATIVE CONCRETE
Micro-toppings may be applied using a squeegee. Photo Credit: Kingdom Products
preparation scenarios and in the cost of material involved in doing a successful repair. Be fair to yourself and to your customer before quoting, by simply knowing what you’re dealing with before the bid.
INTERIOR/EXTERIOR Micro-toppings and engineered cements are commonly used both indoors and out. All of these type coatings will provide a brand-new canvas to an old, worn tattered surface to help you create something new. Occasionally micro-toppings are used to make a new surface look old for different décors and environments. In the past several years micro-toppings have been gaining popularity due to their versatility of use and their ability to restore a worn surface back to
brand-new once again. There are a few things to consider in the selection of your material, the main concern will be the coatings intended usage. Micro-toppings and engineered cements are commonly used in industrial settings in the process of fast-paced construction. The main structure can be built with the practical products necessary to provide strength and cost controlling production methods can be used. Then later, these specialized coatings can be utilized to create or re-create the detail of most any look from smooth slabs of marble, inlaid graphics, logos or even textured tiles, slate or stone. Many times selfleveling versions of these materials are utilized as underlayment’s below carpeting or tiles to smooth
APPLICATION METHODS Application of micro-toppings is easy to do and takes minimal tools. “The only tools required to apply a micro-topping is a pump-up sprayer, a ½ inch drill, a paddle mixer and a hand trowel,” says Tim Frazier, Lead Trainer/ Research and Development at The Stamp Store. He notes some contractors use a squeegee, especially those not familiar with the finishing process. “A contractor can leave a lot of chatter when using a steel trowel because it is bouncing of the sand in the mix. However, a squeegee will smooth over and follow the contour of the sand.” Before applying a micro-topping, Frazier recommends to always prime the floor first because of pin holes. If the concrete is really dry, the concrete will absorb the moisture out of the micro-topping and create additional pinholes and workability issues. “You have about 20 minutes of pot life before the mix is unusable. Only mix enough to apply in that amount of time. And of course, create a sample to share with the owner prior to the complete application.” Contractors will find the return of service factor to be a convenience. “It’s a well-known fact, that being able to walk on the floor the next day can help reduce labor costs and equipment use,” he says. “Additionally, microtoppings can be integrally colored or stained, a big selling point.”
out defects created by fast paced construction methods or retrofit installations. On the residential side of the business, coatings have gained a huge popularity in restoring many of our nation’s foreclosures making the properties once again suitable for the market. Basement floors, patios, decks, walkways and even main living areas have become suitable places for these coatings and micro-toppings.
COLOR/DESIGN Color and design variations can be truly unlimited with micro-toppings and coatings by combining integral pigments, acid stains, acetone based dyes and even metallic effects. Once a floor is correctly resurfaced the end result is a brand new canvas. Often times to keep costs low the coating is simply pigmented before application and once cured, the surface is sealed with a protective clear coat. The final surface finish will vary with the gradations of the coatings. Course ground micro-toppings are suitable for broom finishes, while those with ultra-fine gradations will provide a glass, smooth finish. When you combine these color and finish options with the use of stencils and graphics, the possibilities are truly endless.
CAUTION Chemical stains, reactive dyes, acetone base dyes and water base stains all react and bond beautifully with micro-toppings. You should be advised however that some reactive dyes (even water-based) can pull
38 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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In the past several years microtoppings have been gaining popularity due to their versatility of use and their ability to restore a worn surface back to brand-new once again. Photo Credit: Kingdom Products
substrate stains right through the newly coated floor revealing the details of the floor’s past life. You can see in the photos provided, a substrate that was scrubbed with a silicon carbide impregnated nylon grit brush and given two coats of micro topping to restore the floor. Once the water base dye was applied the old details of the vinyl tiles appeared. This is always a possibility and a concern when doing restoration work so advise your client before you execute this type of restoration job. Add the warning right into your contractual agreements. This will save you down the road if an effect like this occurs. Also be sure to declare up front that routine maintenance will be required to keep the job looking good. Outdoor projects will require a reseal every two to five years depending upon the wear and tear, and the environment. Smooth indoor floors that have excessive wear may periodically need an occasional clear coat or a wax maintenance routine can also be implemented. Simple general routine maintenance like buffing and occasional polishing will be all that is needed for most high traffic floors.
THE SKY IS THE LIMIT If you choose to explore this exciting field, understanding the various effects you can create, the abilities of the materials available and the few limitations of these cement based coatings will help you expand your company’s offerings. You may even be able to start a new division or branch off into a whole new business. Additionally, consider offering maintenance services to give you the opportunity to keep what you installed looking great and build great customer relations which will in turn lead to increased business.
Stop Sealer Failures with StampShield For concrete/pavers & natural stone Specifically designed for use on stamped concrete, pavers and natural stone to provide stain protection by penetrating and chemically reacting with the natural materials found in concrete and stone. • Permanent part of the surface • Will not chip or peel • Resistant to all common staining agents • Easy application • Color enhanced surface without thick plastic looking build • Remains breathable will not white out from trapped moisture
• Can be used for rejuvenating existing solvent based sealers. • Can be applied to a damp surface (no standing water) • Application temps between 35F—95F • Water proof in 10 min. Walkable in 20-30 min. Traffic in 2 hours.
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Ed. Note: Bart Sacco is the president of Kingdom Products and can be reached via e-mail at bsacco1@concrete-texturing. com.
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www.forconstructionpros.com/concrete | April/May 2015 | Concrete Contractor 39
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DECORATIVE CONCRETE
By Ryan Olson
Decorative Surface Solutions Group Aims to Capitalize on GROWTH
The introduction of a buying/marketing group focused on four distinct concrete market segments hopes to improve the industry and bring together suppliers and contractors.
C
ontractors looking to connect with the industry’s best suppliers across several channels now have an option with the introduction of the Decorative Surface Solutions Group (DSSG), a buying/marketing group serving four distinct markets—interior/ exterior architectural concrete, site and structural concrete, large commercial flooring contractors (in the space), and non-traditional flooring contractors. “These alternative surfaces to traditional flooring are relatively young and still somewhat fragmented,” says President and CEO, Curt Thompson. “We see an opportunity to bring both suppliers and contractors together to improve the overall industry and help capitalize on the tremendous growth in these segments.” The DSSG was founded by three business partners with unique yet complimentary backgrounds. Thompson is a long-time flooring industry veteran who has run businesses/brands on the manufacturing side as well as one of the largest wholesale flooring distributors in the country. This blend of experience has given him insight into the benefits of buying groups on both the supplier side and the customer side. Jonathan Vasquez and Mike Price are the other partners, as well as owners and founders of Bay Area Concretes
(Livermore, California)—one of the leading architectural concrete contractors in the country. “We want to help continue to develop the concrete and alternative surface category by growing the best-in-class on the supplier side and the contractor side,” Thompson says. “We provide services, relationships, and process improvements that help them work on their business rather than in their business.” It’s important to note, this model is not new. It has been a highly effective approach in other traditional markets. Thompson says participation in DSSG takes vision on both the contractor and the supplier level.
HOW DOES IT WORK? As an organization, the DSSG strives to establish relationships with the best suppliers in each of the four categories the group participates in. Many of these suppliers cross over and serve multiple channels. Once
Pictured from left to right are the founders of the Decorative Surface Solutions Group, Jonathan Vasquez, Curt Thompson and Mike Price. Photo Credit: Decorative Surface Solution Group
these relationships are established the DSSG will work to negotiate best-in-class pricing and programs to support its members. In turn, members work to support these approved suppliers wherever possible in their business. There are added incentives based on purchases that members can enjoy as they continue to grow their business. Additionally, relationships have been developed with less traditional suppliers (think insurance, etc.) that help members with their day-to-day businesses.
CONTRACTOR MEMBERS Thompson says target members are not identified by size but rather their position in the markets they serve. “A mid-size contractor in a small to mid-size market has as
40 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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much to offer and benefit from the group as a large scale operator in a large market. Obviously, the smaller contractors can see the benefits of the collective group’s buying power, which can have a substantial impact on their bottom line.” For larger contractors, these benefits are scaled up based on their volume. Thompson says there are key attributes they look for when considering a contractor for membership – willingness to share their knowledge, shared vision of the market, excellent financial standing with the supplier community, and generally good business people that others will enjoy being around.
SUPPLIER MEMBERS The DSSG looks for suppliers that are best-in-class. In each product space, the group selects a couple of options and pursues these suppliers. “Contractors like some level of
choice so we help narrow this down for them by identifying which suppliers we think can support them the best,” Thompson explains. “Some of our suppliers are regional in nature but the majority of them serve North America. Suppliers can participate at different levels financially but it’s ultimately up to them to provide a compelling sales story to our members.”
BENEFITS OF DSSG The benefits to member contractors can be categorized in three areas – margin improvement through consolidated purchasing of best-inclass products, process improvements, and peer-to-peer networking. For suppliers, it’s all about positioning themselves as best-inclass with the group’s members. Supplier partners see their selling cycles reduced by being a DSSG approved vendor. Additionally, many of the group’s suppliers see opportunity across new categories
where their products may be a great fit but have had less exposure there.
HOW TO JOIN DSSG To become a member, the group has established a vetting process beginning with a general question and answer dialogue. Ultimately, the prospective member is presented to the group’s Charter Members for approval. Prospective supplier member go through a similar process. “We think it is critical that our industry remain focused on improving our deliverables so this expansion continues. The time is perfect to help start consolidation at the contractor level and the supplier level,” Thompson explains. “Working together will help our industry grow.”
Ed. Note: Contractors interested in joining the DSSG can contact Curt Thompson directly at ct@dssgteam. com.
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www.forconstructionpros.com/concrete | April/May 2015 | Concrete Contractor 41
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PRODUCT FOCUS
By Tom Oury
How to Justify Your CAPITAL EQUIPMENT COST As your market improves, you may find yourself wrestling with whether or not it makes sense to own your own concrete pump. One contractor expressed his situation as follows.
B
usiness is so good, we are placing concrete every day. To maximize revenue and service to customers, we need concrete placement equipment on demand. Our local pumper is top-notch; he almost always finds a way to get our work done. But, we are not the only busy concrete contractor and it is reasonable to expect that his schedule will impact our schedule at some point this season. My accountant thinks we are paying too much rental, and that we could use some depreciation? Are we paying enough pump rental fees to justify purchasing our own pump?
REASONS TO RENT PUMPS • You have access to the pumper’s fleet when you need more than one. • You have no maintenance costs. • You can rent the right boom length for the job. • Rental fees are deductible so it reduces your taxable income.
REASONS TO OWN • Control your schedule • A new pump is a like a billboard for your business that advertises your commitment. • Capitalize on the profits of pumping concrete. Total Cost of Ownership and Net Present Value are standard financial tools used to analyze these types of decisions. The TCO gives you a more
Figure 1
NPV = SUM OF DISCOUNTED CASH FLOWS The time-discrete formula of the net present value
t=the time of the cash flow i=the discount rate or rate of return or opportunity cost R=the net cash flow (cash inflow - cash outflow at time T) If…
It means…
Then…
NPV > 0
the investment would add value to the firm
the project may be accepted
NPV < 0
the investment would subtract value from the firm
the project should be rejected
NPV = 0
the investment would neither gain nor lose value for the firm
the project may or may not be done?
complete picture of the costs involved in owning the equipment and is helpful in comparing similar alternatives. The NPV helps you predict whether or not a particular decision results in a positive net present value. Net Present Value (NPV) is defined as the sum of the present values (PVs) of individual cash flows related to a project or decision. NPV is a central tool in discounted cash flow analysis and is a standard method of using the time value of money to appraise long term projects or decisions. (See Figure 1)
TOTAL COST OF OWNERSHIP Total Cost of Ownership is a philosophy, methodology, or tool for
analyzing all of the relevant quantitative and qualitative costs of an acquisition, project, investment, or relationship for the purpose of making a decision. • Looks beyond/deeper than just the purchase price. • Seeks to understand value of competitive sales claims. • Considers ‘value’ of partner relationships. • Includes relevant information that is often ignored such as residual value or resale value. For this situation we will define Total Cost of Ownership as: TCO = (A – R) + O – DTV TCO = (Acquisition minus Residual Value) plus Operating Costs
42 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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Figure 2
Sales and Utilization Rate
Avg Units
Revenue
Hrs / Month 102
Hrly
$165
6
$990
Avg Daily CY
$3.00
75
$225
Travel
$165
1.5
$248
1275
$1,463
Total Revenue
CY / Month
Daily
Days / Month
Monthly
Annual
5 years
10 years
$1,463
17
$24,863
$273,488
$1,367,438
$2,734,875
1275
1700
18700
93500
187000
CY
minus Depreciation Tax Value. Acquisition minus residual equals machine sales price plus interest minus the residual value at the end of the evaluation period, whether five or ten years. Operating costs equals fuel, oil, grease, pipeline, wear parts, repair parts, operator wages, mechanics wages, insurance, licensing. Depreciation value equals tax value of depreciation using five years straight line depreciation. For both the NPV and TCO analysis, it is necessary to make educated assumptions about: • Decision time frame – usually five or ten years. • Projected equipment residual values at these intervals. • Equipment utilization • The hourly value of the equipment you want to purchase so you can assess revenue generation (inflows). • Complete operating costs driven by your utilization: — Fuel, oil,
grease, pipeline, wear-parts, broken stuff, operator wages, mechanic wages , insurance and license. With these predictable figures, we are in a position to build a spreadsheet model that will predict TCO and NPV. The Sales and Utilization worksheet forms the basis for establishing revenue generation and it drives operating costs. (See Figure 2) In this example we are making the assumption we can utilize a 36 Meter pump 17 days per month/11 months per year – averaging 75 cubic yards per day. For revenue we are using the
average rate we pay for this size pump in our market. To begin the TCO analysis we first establish the acquisition cost of the machine we are considering and adjusting for residual value at the conclusion of our five year analysis period. (See Figure 3) We are also showing 10 years. In this example we are buying a new Schwing 36X concrete pump and assuming its five year value will be 55% of new. The operating costs flow directly from utilization and the cost assumptions made concerning unit costs; fuel, operator, parts, etc. The TCO can be a very good tool
Figure 3
Acquisition Costs Adjusted for Residual Value Equipment Cost
$475,000
Loan Repayment 5 Years 6%
1.9330%
Montly
Annual
5 Years
10 Years
$9,182
$110,181
$550,905
$550,905
FMV
residual
NET 5 Year
($237,500) ($142,500) $313,405
NET 10 Year
Figure 4
$408,405
Operating Costs Unit Costs
Units
Monthly
Annual
5 Years
10 Years
Fuel, Oil, Grease
$125
17
$2,125
$23,375
$116,875
$233,750
Wear Parts / CY
$0.25
1275
$319
$3,506
$17,531
$35,063
Repair Parts
$0.25
1275
$319
$3,506
$17,531
$35,063
Repair Labor / CY
$0.25
1275
$319
$3,506
$17,531
$35,063
Operator / Day
$500
17
$8,500
$93,500
$467,500
$935,000
License
$75
$900
$4,500
$9,000
Insurance
$500
$6,000
$30,000
$60,000
$12,156
$134,294
NET 5 Year NET 10 Year
$671,469 $1,342,938
www.forconstructionpros.com/concrete | April/May 2015 | Concrete Contractor 43
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PRODUCT FOCUS Figure 5
Depreciation & Taxes 5 Year Straight Line
Asset Value
Tax Rate
DTV
$475,000
-35%
-$166,250 TCO 5 Years
5 Years
10 Years
($166,250)
($166,250)
$818,624
TCO 10 Years
$1,585,093
Figure 6
Year
Revenue
Purchase of Equipment
Resale of Equipment
Operating Costs plus monthly payments
Depreciation Tax Value
Total Cashflow
Present Value Interest Factor
Discounted Cash Flows
0 1
$273,488
($244,475)
$33,250
$62,263
0.926
$57,655
2
$273,488
($244,475)
$33,250
$62,263
0.857
$53,359
3
$273,488
($244,475)
$33,250
$62,263
0.794
$49,437
4
$273,488
($244,475)
$33,250
$62,263
0.735
$45,763
5
$273,488
($244,475)
$33,250
$299,763
0.681
$204,138
NPV
$410,353
for comparing manufacturer specific costs advantages such as fuel consumption, repair parts, repair labor, and resale value. (See Figure 4) It should be noted that this table smooths osts into neat and tidy monthly costs, and that real life has more peaks and valleys. Replacing a boom pipe might be an annual event, or bi-annual, but the costs could be viewed as happening daily, monthly, etc. Back to your accountant saying you could use depreciation. Inherent with machinery investment is the depreciation expense that comes with it. This expense reduces your taxes and therefore has a value that is predictable, based on your tax rate, depreciation method, and the value of the equipment being depreciated. In this example we’ve use a tax rate of 35 percent and straight line depreciation (in the NPV). It might seem odd that this shows up as an inflow, or cash positive, but keep in mind we have already fully accounted for the acquisition cost of the machinery above. (See Figure 5) Now that we have a better view of the total cost of ownership, let’s
$237,500
consider whether this is a moneymaker by placing our inflows / outflows into a NPV table. The present value interest factor is based on an eight percent discount rate. (See Figure 6)
CONCLUSION Based on our assumptions regarding utilization and operating costs we are predicting a very positive NPV of $410,353. This is a very strong indicator that the decision to own this equipment adds value to your firm. There’s no doubt every situation has its own complexities. There are many more facets to the decision and it makes good sense to challenge some of your assumptions and do several versions of the TCO and NPV. Is the utilization figure too high? Are the operator costs in line? Is the rental rate correct? To summarize the Capital Equipment Cost Justification outlined above: • Assess expected utilization and the rental value of the machine you are considering. • Estimate the operating costs
using your utilization. • Consider the unique value claims of the model(s) you are considering. Does one machine hold value better? Are there operational cost advantages? Fuel? Parts? Repairs? Will some features help you improve utilization? • Talk to your accountant about depreciation and its value in your situation. • Talk to your sales representative who will be able to help construct comparative TCO’s and NPV’s for your situation. • Use some form of Total Cost of Ownership worksheet and a Net Present value assessments AND challenge what you come up with, then... • Invest in the machine that best fits your use profile, but only if the NPV is positive – using your best view of the TCO. Ed. Note: Tom Oury currently serves as the Central Region Sales Manager for SCHWING America. Oury can be reached at TOury@schwing.com.
44 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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Uses 21 ga. wire ties up to #7 x #8
Uses 21 ga. wire ties up to #3 x #3 Uses 21 ga. wire ties up to #5 x #6
New 21ga.wire TW898 series
NEW
Use Your Smart Phone for detail
TW898 replaces TW897A and works with RB397, RB517, RB217 and older models
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FOUNDATION Q&A
By James R. Baty II
No Reason To Not Inhale
The CFA offers the following advice regarding the use of fiber-reinforcement and the misguided concerns that exist as well as the misrepresentation of their intended use.
Q
I am having a driveway replaced and am concerned about the use of those glass fibers that my contractor is recommending. What do they really do and shouldn’t I be concerned about breathing them in over time?
A
NSWER With increasing frequency, we are hearing from homeowners about the presence of fibers in concrete. While it is somewhat surprising that this issue could actually be increasing in its frequency, it is also disconcerting that it is an issue at all. In our most recent contact, the homeowner had in mind fiberglass batt insulation and the warnings heard over time about not wanting to inhale the fibers when working in the attic. So from this perspective, it was clear that homeowner and proposing contractor were on different pages, perhaps even different books entirely when it came down to the use of a product. In the new ACI 332 Guide to Residential Concrete Construction, available later this year, ACI 332 Committee members offer a direct discussion of the use of fibers in residential concrete. There are two major classifications for fibers, micro and macro and in each classification the fiber can be described as being mono-filament or fibrillated. Microfibers are intended to provide precrack stress control for plastic shrinkage and lessoning stress relief for settlement or relaxation of the concrete during its plastic stage. These are the more common fibers seen throughout the residential industry
The CFA continues to hear from homeowners regarding health concerns of fibers used in residential concrete. It should be identified to any homeowner the fibers added to concrete pose no health threat. Photo Credit: Forta Corp.
today. The macro-fiber, when offered provides similar performance for intended use to the micro-fiber but at a greater degree of control and they provide post-crack control for temperature and shrinkage when the dosages are high enough to provide adequate tensile capacity. In the case of the homeowner asking this most recent question, what was in mind was that “fibers” were the fine, spun-glass fibers found in the insulating blankets commonly placed between studs for a wall or laid between the joists in an attic. It should be clearly identified to any homeowner that the synthetic fibers added to concrete, even when micro in nature, are thicker and stronger than the fiber elements that get in your skin from insulation. While there are glass fibers, they are not very common. Although the fibers may be present at the surface of the concrete to some extent they will neither become airborn nor be cause for concern of brittle impalement or puncture. When asking of the contractor why glass fibers might be present in
the driveway slab, the response was given that they would control cracking in the slab and would be more economical than placing all that steel wire. To the homeowner, the evaluation of steel versus small randomly dispersed fibers in a concrete mix did not equate. It is true enough that the concern is warranted and this is largely due to the proposing contractor’s misconception of the behavior of fiber-reinforced concrete and the intended purpose of reinforcement in concrete as a whole. ACI 544.1R and NRMCA CIP24 are the recognized authoritative documents for the performance of fibers in concrete. In both documents, synthetic fibers are limited in their benefit to hardened concrete as lowering permeability and increasing resistance to shattering, abrasion and impact. In other words, synthetic fibers strengthen the surface of concrete and lessen the formation of surface cracks that lead to water penetration. This is definitely a positive for driveway slabs that suffer over time from the presence of de-icing
46 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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salts brought in from the streets or applied by the homeowner as well as spalling from the effects of freezing and thawing. However, these documents also indicate that crack control is not an attribute of the commonly used synthetic fiber. A contractor in the concrete industry, you are fully aware of two truths with concrete: 1) It gets hard. 2) It cracks. Concrete cracks, and we are powerless to do anything about that. That is, we must assume that concrete will crack and therefore it must be augmented in its design to control the significance of that cracking. This is where steel reinforcement is essential. The homeowner was told that glass fibers would be an economical way of eliminating the steel necessary to control cracking. The result of this decision would most certainly be replacing that driveway in a few short years, especially since the contractor was not likely to properly joint the slab in small enough sections to control the cracks that would soon develop. NRMCA CIP24 cautions the contractor to make sure a manufacturer supplies documentation to prove that any fiber can function as a nonstructural temperature or secondary reinforcement. There are few options out there that can produce such evidence. Instead, the quality-minded contractor should consider a two-part system that implements steel reinforcement bars along with the surface durability protection of a glass fiber to deliver an optimum slab solution. What cannot be overlooked in the process of delivering a quality slab to a customer is the base preparation, elimination of active water below the slab, properly located and spaced steel reinforcement bar pattern, control of the ratio of water to cementitious material in the mix and properly spaced control joints cut early in the slab. These are the best methods to ensure a long-lasting concrete slab.
Jim Baty is the Executive Director for the Concrete Foundations Association after having served as Technical Director since 2001. He is currently chair of ACI 332 and a voting member for ACI 306 with priorities of establishing better guidance and structure for residential concrete construction. For more information on this topic, contact Jim Baty at jbaty@cfawalls.org.
Find out more at www.cfawalls.org. The CFA is a national association for professionals with the mission to support the cast-in-place contractor as the voice and recognized authority for the residential concrete industry. ACI 332 is the Residential Concrete committee for the American Concrete Institute and as a code committee is seeking professionals from all aspects of this industry with an interest in participating in the development of expanding and strengthening this concrete code.
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www.forconstructionpros.com/concrete | April/May 2015 | Concrete Contractor 47
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By Jeff Bonkiewicz
What’s Old Becomes
NEW AGAIN
A hospital floor deemed unfit to polish is restored due to the application of a decorative, polishable overlay wear topping designed specifically for such situations.
T
he Hudson Hospital expansion project called for new administration and clinical wing construction, including hallways, lobby, waiting room, and stairs. McGough Construction was the general contractor on the job. Concrete Arts, a decorative and polished concrete firm local to the Hudson, Wisconsin area, has had an existing relationship with McGough for years, and they hired on Tom Graf and his crew, owner of Concrete Arts for their expertise in polished concrete craftsmanship and concrete design. The project scope included dyeing and polishing both new and existing concrete floors in the lobby, hallways and
waiting areas, as well as creating and polishing structural stairs. There was just one problem: the link between the old and the new concrete needed new mechanical trenches dug through the concrete. These trenches were needed to accommodate new electrical and plumbing runs. Based on that, Graf decided the floor was not a good candidate to polish. Additionally, the project schedule was tight, and the owners were looking to occupy the new spaces by mid-fall. Graf analyzed the job and recommended Durafloor TGA, a decorative, polishable overlay wear topping designed specifically for such situations. This versatile product could be placed in both new and damaged
The restoration of the concrete floor at the Hudson Hospital, Hudson, Wis., utilized Durafloor TGA, a decorative, polishiable overlay wear topping designed for such situations. Photo Credit: Laticrete International
spaces in the lobby and the hallways—all high foot traffic areas— with fast turnaround time.
SURFACE PREP – MILLING THE CONCRETE Concrete Arts’ crew had to mill down the concrete surface 3/8 in. in order for the substrate to accept the TGA overlay, which was very time consuming. They then filled and repaired all cracks with L&M RESTORE. Next, the team re-saw cut and honored all existing joints and filled them with L&M JOINT TITE 750.
48 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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Concrete Grinding Just Got a Whole Lot Easier! The Scan Combiflex 800DSP is a new type of concrete floor grinder unlike anything the industry has seen before. This machine is engineered with an integrated computer system and smart floor grinding and polishing technology that guides you through the entire job, virtually eliminating all guesswork from the grinding and polishing process.
FROM SCANMASKIN
The Scan Combiflex 800DSP features a built-in touch display that shows tool wear, tool lifetime, machine speed, and grinding power. It provides recommendations for the kind of tool that should be used on the machine as well as the speed to reach an optimal wear. The 800DSP senses the hardness of the concrete surface and calculates the speed necessary to reach as optimal a performance as possible. It can also estimate how much time is left before the tool needs to be replaced. A series of sensors throughout the machine continuously transmits data, providing operators the critical information they need to do the job right. Instead of completing a job only to discover that it could have been done better, the 800DSP provides clear recommendations and warnings so you can make the right decisions at the right time.
« Senses the hardness of the concrete surface and calculates the speed necessary to reach as optimal a performance as possible.
AS SEEN AT WORLD OF CONCRETE 2015!
« Estimates how much time is left before the tool needs to be replaced. « Three-head planetary drive system with 9-inch heads for increased efficiency and smooth operation. This allows the 800DSP to grind or polish at higher speeds with minimal vibration and stress. « With a 32-inch grinding path, the ability to hold up to 18 tools, and a weight topping 882 lbs, the 800DSP is ideal for large commercial applications. Available in a 400V and 230V 3-phase.
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Call your Jon-Don Concrete Sales Rep to find out more about the Scan Combiflex 800DSP!
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At the completion of the project, the floor exhibited a homogenous look and feel of approximately 3,500 sq. ft. of flooring space. Photo Credit: Laticrete International
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Concrete Contractor: Concrete Arts Floor Age: New and existing concrete Owner: Hudson Hospital, Hudson, Wis. Total Sq. Ft.: 3,500 sq. ft. in the lobby, hallways and waiting areas. Work was performed in two phases: each phase was finished in two weeks.
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From there, they applied L&M EPOPRIME epoxy primer onto the properly prepared surface and seeded it with silica sand to rejection. After allowing the sanded epoxy to dry, the excess aggregate was vacuumed and broomed from the surface. After surface prep was complete and the sanded epoxy cured, Concrete Arts’ crew then mixed and placed the Durafloor TGA polishable overlay. After allowing the freshly placed topping to cure for about 16 hours, the surface was ground through the diamond chain to a 1,500 grit full polish, with two coats of L&M VIVID DYE applied to match the existing concrete’s color. The crew locked-in the dye and densified the overlay with
The solution provided the hospital owners with a nearperfect link between the existing concrete floors and the new Durafloor TGA floors. Photo Credit: Laticrete International
“Custom Engineered Solutions Since 1910” 50 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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L&M LiON Hard hardener densifier. Finally, the crew applied L&M PERMAGUARD as a stain protector for the newly polished surface. Since the stair treads offered by competitors did not match up with the newly polished floor, Durafloor TGA’s versatility enabled the Concrete Arts’ crew to pre-fabricate the stairs to an exact match of the polished concrete floor. Cranberry glass aggregate seeded into the wear topping created the stair treads. The structural stairs were polished on three sides spanning 6.5 ft. each. The front portion of the stair treads were sandblasted for slip resistance.
Durafloor TGA’s versatility The solution provided enabled the Concrete Arts’ the hospital owners with a crew to pre-fabricate the near-perfect link between stairs to an exact match of the existing concrete floors the polished concrete floor. and the new Durafloor Photo Credit: Laticrete International TGA floors. It exhibited a homogenous look and feel of approximately 3,500 sq. ft. of flooring space. Hudson Hospital administration and the McGough project managers were very happy with Concrete Arts’ work. Their double shifts paid off by showing the results of a beautiful, durable, near-match of the existing decorative concrete. By recommending, placing and polishing the decorative Durafloor TGA overlay wear topping, Concrete Arts’ crew turned-over the Hudson Hospital project on time. Speaking to the distinctiveness of the polishable wear topping, Graf states that there is no other cementitious flooring product on the market that resembles such unique, durable, decorative concrete. Hudson Hospital’s new addition opened in October 2014.
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www.forconstructionpros.com/concrete | April/May 2015 | Concrete Contractor 51
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DUST COLLECTION Husqvarna DC 6000 The new DC 6000 system matches the company’s Dual Drive grinding machines, the Husqvarna PG 820 and PG 680. The Husqvarna DC 6000 will replace the DC 5500, a vacuum cleaner with a traditional two-filter system. The patented double shell cyclone technology with auomatic filter cleaning takes the DC 6000 to the next level. • Double shell cyclone technology with automatic filter cleaning, which allows: Constant high air flow – 700 m3/h • Less dust left on the floor, contributing to time savings and a healthier working environment • Automatic back-flush • HEPA 13 rated filter • Longopac bag system ForConstructionPros.com/11447350
T8600 Propane Dust Extractor Control dust on concrete grinding projects without electricity with the new T8600 Propane dust extractor. • 18 hp Kawasaki motor with a direct-driven turbine • 410 cfm and 115 in. of water lift • Individually tested and certified HEPA filters • Coated polyester pre-filter socks • Drop-down disposal system • Longopac collection system • JetPulse filter cleaning ForConstructionPros.com/11142296
SASE BULL 1250EBS Dust Collection System SASE Company Inc. introduces the BULL 1250EBS Dust Collection System now with the Elongated Bag System. The BULL 1250EBS can be used with the SASE PDG 8000, PDG 6000, and all other industry 32 inch diamond grinders. • Elongated bags feature over 42 sq./ft. of filter area • Quiet – only 78 dB • Secondary HEPA Filtration • Manual filter shaker system is durable, dependable and easy to use • 8.5 hp regenerative motor • Soft start • Include 50 ft. of 3 in. hose and 100 ft. of heavy duty power cord • Constructed of 14 gauge steel for longevity in industrial use • Weight: 500 lbs. • Air flow: 388 CFM ForConstructionPros.com/12056920
Makita Expands Lineup of Dust Extraction Solutions Makita has expanded its line-up of dust extraction solutions for concrete contractors with a new Dust Extraction Attachment, model 196571-4, for use with demolition hammers and rotary hammers (accepts SDS-MAX). The new Dust Extraction Attachment is engineered to help reduce dust created from breaking and chipping concrete. • 6-piece kit for use with a jobsite vacuum (sold separately) • Compatible with Makita SDS-MAX Rotary Hammers and Demolition Hammers • The Dust Extraction Attachment kit and includes a dust cover, hose (62-1/2” long), hose holder for power cord, hose holder for “D” side handle, hose holder for straight side handle, and hose joint (1-7/8” ID, 2” OD) ForConstructionPros.com/11364543
Pulse-Bac SelfCleaning Vacuum Pulse-Bac the original and patented self-cleaning vacuum. Most vacuums can lose up to 50 percent of their suction as the filter clogs and this can happen quickly. Forcing you to clean the filter which is time consuming, messy and takes away from the job at hand. • Pulse-Bac’s technology is different, it keeps filters clean and suction consistent. • Plus it’s 100% automatic, no heavy compressor, button to stop and push or lever to pull. ForConstructionPros.com/12057256
SEARCH for more information online using the unique URL under each product.
52 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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GRINDING AND POLISHING MACHINES VACUUM SYSTEMS
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photo credit: Flagship Commercial Flooring
New chain planetary drive system and new access window on the top side of the machine base minimizes maintenance time and increases productivity.
To learn more, scan the QR code or visit www.superabrasive.com
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By David Stephenson
The State of Maintenance and POLISHED CONCRETE FLOORS As a contractor, understanding the maintenance procedures and its role in your contracting work will lead to greater success.
A
s an independent consultant most of my firm’s time is spent assisting retailers with managing their flooring programs. I regularly assist with specifications and quality control of the installation, but maintenance by far is where I spend the majority of my time. Polished concrete in its current form has been around for about 15 years in the U.S. For a long time, the process of mechanically polishing concrete was sold to consumers as a “maintenance free” floor. To my knowledge, there is nothing in the world that is maintenance free. Generally, contractors and installers do not really have a good understanding of how maintenance fits into their work. When a retailer is considering polished concrete flooring, maintenance is generally the driving factor.
VCT VS. POLISHED CONCRETE In the retail world, VCT (Vinyl Composition Tile) remains the
dominant floor covering in use. A VCT floor costs $3.00 per foot to install on average across the country. Standard VCT has to be waxed, as the finish provided by the factory does not last long as the wearable surface. Maintenance for VCT averages $2.00 per foot per year. The cost of maintenance includes scrubbing the floor nightly, buffing the floor regularly to remove scuffs from foot traffic and regular strip and wax services. Polished concrete has an average install cost of $5.00 per foot in a remodel environment. If installed at the time of a remodel (versus new construction which generally has a cheaper price) polished concrete costs $2.00 more per foot to install, but a good maintenance program for polished concrete has an average cost of $1.00 per foot per year. In two years, the difference of the install costs has been recovered. From that point forward, the floor maintenance is actually saving money for the customer. Generally, VCT lasts seven to ten years before it deteriorates to the point where it needs to be replaced. Removal of VCT averages $1.50 per square foot. Add removal to the install cost of $3.00 and you get a removal and replacement cost of $4.50 per foot. Polished concrete never has to be completely redone and there is no removal. The average refurbish price for a polished concrete floor is $1.50 per foot. That is a $3.00 per foot savings every ten years on top of the $1.00 per foot per year savings of the standard maintenance.
To give you a real world comparison let’s look at a grocery store. The average store has 45,000 square feet of sales floor, of which 35,000 square feet is exposed (not under shelving or displays). This store will spend $135,000 ($3.00 per foot by 45,000 feet) initially to install VCT and then over the next ten years they will spend a total of $700,000 (exposed area of 35,000 feet by $2.00 per foot) on maintenance. When it is time to replace their VCT they will spend another $202,500 ($4.50 by 45,000 feet) for removal and replacement.
As a contractor, when you finish a project, one of the most important things you can do is discuss maintenance with your customer. Therefore, their total cost of their VCT floor is $1,037,500 over ten years. A polished concrete floor would cost them $225,000 (45,000 feet by $5.00 per foot) to install then over ten years they will spend $350,000 (35,000 exposed floor space by $1.00 per foot per year)to maintain
54 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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their floors. At ten years, they need to refurbish the floor so they will spend another $67,500 (45,000 feet by $1.50 per foot) to bring the floor back to where it was at construction. The total ten-year cost is $642,500. The polished concrete saved the store $395,000 over ten years. That is called ROI or Return on Investment. This is the single largest driver of polished concrete flooring. This model only works if the polished concrete floor is mechanically finished well so that it can be maintained properly. I recently reviewed thirty stores for one retailer. Of the stores I looked at, approximately two-thirds were not mechanically finished well enough to be maintained using normal procedures. The floors looked dull, held dirt and grime, and in some cases had safety issues as a result of workmanship. As an industry, if we want to survive, we cannot turn floors like this over to the customer. When we do, the operations groups (which is the real power) get frustrated and start pushing to go away from polished concrete. If the price point that the customer is willing to pay does not allow you to correctly install a â&#x20AC;&#x153;fully processed seven to nine step polished and ground systemâ&#x20AC;?, there are several options in my opinion. Explaining the ROI to the customer and showing the value of your full process is one option. A second option is to CLEARLY lay out your plans for the lower cost system and talk about the life cycle cost of going the cheaper route. The third option is to walk away from that project. Believe me, I know it is hard to walk away from potential revenue, but if a project is not properly done the resulting loss of revenue on multiple future projects will not be sustainable for your company or the industry in the long run. Over the last few years, I have watched this scenario play out with several retailers. Instead of adding millions of square feet of polished concrete into the available jobs, retailers do a few floors, realize that
they are not getting the ROI out of them and go back to VCT. Do not kid yourself into thinking that the look of polished concrete sells itself. VCT is much easier to control the look, especially in a remodel situation. The benefit of concrete flooring is in the savings at the bottom of the expense line. The flooring maintenance is intimately tied to new projects being constructed.
LONG-TERM MAINTENANCE In order for the polished concrete industry to survive and flourish, long-term maintenance has to take some huge steps towards standardization and ease of use. The best maintenance products for polished concrete floors are made today by chemical companies that are already in the concrete business. Some of the larger construction chemical companies make cleaners that have densifier and stain protection in them. These cleaners do not etch the
surface of the concrete, but still do a great job of removing grease. These are extremely important when taking care of a polished concrete floor, especially in retail environments. Currently these chemicals are available either direct from the manufacturer or through construction supply companies. The problem is that janitorial contractors do not generally shop at construction suppliers, instead they shop at janitorial suppliers and they do not try to find a manufacturer to purchase from directly. In the construction industry, contractors find suppliers that they like and buy from them regularly. Janitorial contractors likewise follow the same process for purchasing. They have suppliers that they have been buying from for a long time and changing is difficult. In order for the polished concrete maintenance to succeed, one of two things needs to happen concerning the chemical supply chain. Either current janitorial
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chemical manufacturer’s need to make cleaners that are more effective at removing grease, maintaining shine and replenishing stain protection or polished concrete chemical manufacturers need to do a MUCH better job of placing their products in janitorial supply companies so that these chemicals are more readily available to janitorial contractors. Current chemical manufacturers will need to consider the packaging of their cleaning products. Companies that make janitorial cleaners of all types figured out long ago that if too much or too little of their product is used, the results change dramatically. Most of the larger manufacturers offer “portion control” systems to make sure that the correct amount of chemical is used. Only one current polished concrete chemical manufacturer has addressed the issue that I am aware of. As it is not reasonable to install
new portion control systems in each store, chemical is being packaged in single use packets with pre-measured amounts. I know of one other manufacturer that is working towards a better system as well. The standard delivery method is five-gallon buckets of product. It is impossible to properly measure the correct amount of cleaner using a five-gallon bucket and pouring cleaner into an auto scrubber or mop bucket. If improper amounts of cleaner are used it will affect the life cycle cost of the floor in multiple ways and erode some of the advantages that polished concrete has over other flooring types.
CONTRACTOR’S NEED TO DISCUSS MAINTENANCE As a contractor, when you finish a project, one of the most important things that you can do is to discuss maintenance with your customer. Do not settle for having a short
conversation. Invest some time and come up with a simple maintenance document that you can email to everyone who is involved with the project. This includes owners, contractors and architects. Recommend cleaners that match up with your densifier and stain protection so that a single system can be implemented throughout. The customer will appreciate this tremendously. Set up a short training class for your customer as well. By doing this, at least if they use cleaners that are not recommended, you could remind them and show them what was provided when the project was completed. Turning over a floor to a customer without a maintenance program is like building a car and selling it without a manual. You can build a great car, but if the owner does not change the oil, use the right fuel and perform normal routine
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INDEX maintenance the car is not going to stay operational for very long. A polished concrete floor is the same way. Maintenance is the single biggest reason that projects are available for construction, so take the time to do your part in assisting the customers with maintenance. Whether you are a customer, general contractor, contractor, manufacturer or supplier, there are key things that you can do to help maintenance move forward in this industry.
Ed. Note: David Stephenson is president of Polished Concrete Consultants, LLC. He can be reached at david@polishedconsultants.com.
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THE LAST PLACEMENT: BACK TO BASICS
By Dustin Thomas
How to Apply Concrete Dyes When Grinding and Polishing
T
here are a variety of ways concrete dyes can be applied, depending on the size of the job and the desired end result. Typically a HVLP (high-volume low-pressure) sprayer is the best applicator. Remove all dust and debris from the floor so you are working with a relatively clean surface. Use an auto-scrubber for best results. It is best to apply concrete dyes around the 200 grit-honing step for dense/ harder concrete or 400 grit for porous/softer concrete when use in a concrete polishing process. It is also important to test in a small inconspicuous area first to ensure the dye is producing the desired result. All concrete surfaces are different and the color can change depending on the age of the concrete, the base tint or shade of gray of the slab to be dyed as well as many other factors. Concrete dyes are available in a few different forms but the most popular are powdered dyes and concentrated colorant. Powdered dyes are solvent-based and acetone is most often used for mixing with the powdered dye. Concentrated colorant concrete dyes are liquid-based and water or acetone can be used for mixing. Both produce relatively the same result, however familiarity with the product is important as well as the specifications of the project. Solvents are sometimes restricted depending on the project’s environment. Mixing the dye is simple. Put the concrete powder or liquid concentrate into a gallon or five gallon container, shake vigorously and let it emulsify for five to 10 minutes for the liquid concentrate. The powder
dyes need about two to three hours to fully dissolve in the acetone before applying. Once mixed, simply pump the sprayer to add the pressure needed to spray the dye onto the concrete surface. Fan tips are not recommended as they tend to leave lines in the floor. Conical tips like the Grey - Patriot tip will give a more uniform pattern and help achieve the recommended 400-600 square feet per gallon coverage rate. When applying the dye make sure to do circular motions about the size of a basketball with the sprayer wand. Also be sure the surrounding areas and walls are covered appropriately. Waterbased dyes need about 30 minutes to dry while acetone has a faster flash time and is ready almost immediately. Once you have achieved uniform coverage and the concrete dye has
When applying dye use a HVLP sprayer and make sure to do circular motions about the size of a basketball with the sprayer wand. Photo Credit: Ameripolish
had time to dry the next step is to densify the floor.”This method of densifying immediately after applying concrete dyes without removing the residual dye is relatively new. This method uses the residual dye to penetrate deeper into the floor for a more vibrant end result. It also saves on “clean up” labor time since removing the residual dye is no longer required. Continue honing and polishing to the level required. The final step is applying a concrete sealer for protection. Ed. Note: Dustin Thomas is the Director of Marketing at Ameripolish.
58 Concrete Contractor | April/May 2015 | www.forconstructionpros.com/concrete
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