Beyond Vertical Concrete Turns Imagination to Reality
30 August/September 2018
#1
in the market!
THE LEADING TRADE MAGAZINE IN THE CONCRETE INDUSTRY
Using MIXED REALITY Technology in Construction 16
Against All Odds: How the Mega Slab Became a
SUCCESS 22
HARLEYDAVIDSON
Showroom Floor Designed to Focus on Merchandise
66 What is the Best System for Polished Concrete Maintenance
72 www.forconstructionpros.com/concrete CONC0818_01_Coverfinal.indd 1
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FOR BEST RESULTS START AT THE BEGINNING
CHOOSE THE BEST CONCRETE VIBRATOR FOR YOUR JOB Concrete vibration helps newly poured concrete become strong and durable. Picking the right one is key to high productivity on the job. Husqvarna can help with our new line of concrete vibrators, which includes Smart High Frequency electric, AME modular flex-shaft, AA mechanical pendulum, and PV pneumatic vibrator options. This wide range of choices means you can find the most productive combination of hose length, tube size and radius of action to complete your work within the shortest time and lowest amount of dips. To find the right combination for your project, call your local Husqvarna representative.
800.255.5040
WWW.HUSQVARNACP.COM hcpcustomer.service@husqvarnagroup.com Phone: 800-288-5040 Copyright © 2018 Husqvarna AB (publ.). All rights reserved. Husqvarna is a registered trademark of Husqvarna AB (publ.).
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August/September 2018 | Issue 5, Volume 18
WHAT’S INSIDE Cover Photo Credit: Barton Malow
Departments 4 Editor’s Letter 6 Legal Matters 8 New Products 60 Foundations Q&A 82 The Last Placement
What’s Online
Cover Story
Avoiding the Legal, Financial and Environmental Consequences of Concrete Washout
22 Against All Odds How the Mega Slab Became a Success
Features 12 Placing Concrete Smarter - Part 2 Part two of a three part series. This feature will take a more in depth look at productivity and quality variables for common slab on grade installations.
16 Using Mixed Reality Technology in Construction Mixed reality and virtual reality in 3D.
30 Beyond Vertical Concrete Turns Imagination to Reality
44 Remote Controlled Demolition Machines Key to Demolition of NBA’s Second Largest . Renovation Project SSD Demolition and Environmental slam dunks the Philips Arena project.
48 Ultra-High Performance Concrete A type of concrete you haven’t heard about, but should.
54 Equipment Specification Guides: Vibrating Equipment
Contractor Forfeits Bid Bond After Mistakenly Leaving Out “Thousand” in Written Proposal A contractor tried to withdraw its bid on a public contract after realizing it left out the word “thousand” in its bid proposal Search: 21012061
A compilation of technical information when choosing your next concrete vibrator.
72 What is the Best System for Polished Concrete Maintenance
When art meets concrete, backyard fantasy escapes can be achieved.
38 To Seal and Protect: 66 Harley-Davidson Preserving Decorative . Showroom Floor Hardscapes Designed to Focus The best way to ensure a on Merchandise hardscape’s lasting appearance is to apply a good sealer.
There needs to be an increased awareness of technology that can help concrete plants and construction firms meet growing demand, without suffering legal, financial or environmental consequences associated with waste disposal. Search: 21016246
Simple, good looking and durable is what the Harley-Davidson dealership owners wanted for their 14,000 sq. ft. Rocklin, Calif. showroom.
A comparison of traditional DIP (Diamond Impregnated Pads) and Composite Resin Abrasives (CRA).
78 Concrete and Silica Three Factors You Need to Know If respirable dust is visible in a work area, adequate respiratory protection should be worn by workers in the contaminated area.
www.forconstructionpros.com/concrete | August/September 2018 | Concrete Contractor 3
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EDITOR’S LETTER Published by AC Business Media Inc.
Technology on
PARADE
201 N. Main Street, Fort Atkinson, WI 53538 (800) 538-5544 • www.ACBusinessMedia.com
www.ForConstructionPros.com/Concrete
I
f there were a general theme for this, the August/September issue of Concrete Contractor, I would say technology in construction is front and center. Over the last few years, we have seen an emergence of technological products that help contractors perform their jobs more efficiently while also saving money. In fact, I was impressed with the technological solutions I saw on display nine months ago at the World of Concrete. On page 16, Joe Nasvik writes about Trimble Connect for HoloLens as well as an attachment to a hardhat for use on a construction site. A camera is included with the hardhat which maps the environment around you, allowing a contractor to see virtual holographic construction objects overlaid onto the location they will be installed on a project. Our Cover Story features a team of 140 contractors called upon to place 256,000+ square feet of concrete. As you’ll learn, the project was built “virtually” before contractors arrived on site. The contractor, Barton Malow, created a 4D model that combined what the project would look like down to the minute. Turn to page 22 to read more. Finally, when the Atlanta Hawks announced a $192.5 million re-imagination of the Phillips Arena Facebook.com/ ConcreteContractor
Advisory Board
PUBLICATION STAFF
Ryan Olson, Publisher/ Editorial Director ROlson@ ACBusinessMedia.com (800) 538-5544
in Atlanta, SSD Demolition and Environmental knew using remotecontrolled demolition machines would improve productivity over hand-held tools, as well as keep workers safe from flying concrete and fall risks. This phase of the project required the demolition of almost 3,000 tons of concrete which needed to be completed in 12 weeks. The contractors plan to use innovative machines was what won the them the job. While these three features highlight the use of new technology, this is only the beginning. Technology is already seeping into other areas including the front office, equipment enhancements and personal protective equipment. Technology is not going away and manufacturers and contractors are learning that new technology is making construction safer and more efficient, which will also lead to more revenue to your bottom line.
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.
Publisher/Editorial Director Contributing Writers Senior Production Manager Art Director Audience Development Director Audience Development Manager ADVERTISING SALES (800) 538-5544
Lynne Woodworth Eric Servais Erica Finger Nikki Lawson Amy Schwandt Sean Dunphy Denise Singsime National Automotive Sales
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Nick Raether nraether@ACBusinessMedia.com Monique Terrazas mterrazas@ACBusinessMedia.com Larry Stewart lstewart@ACBusinessMedia.com Kimberly Hegeman khegeman@ACBusinessMedia.com
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PO Box 3605, Northbrook, IL 60065-3605, Phone: (877) 201-3915 Fax: (847) 291-4816 • circ.ConcreteContractor@omeda.com REPRINTS Ryan Olson, (800) 538-5544, ext. 1306 , rolson@ACBusinessMedia.com LIST RENTAL Jeff Moriarty, SVP, Business & Media Solutions Infogroup, Phone: (518) 339-4511 Email: jeff.moriarty@infogroup.com AC BUSINESS MEDIA INC.
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Published and copyrighted 2018 by AC Business Media, Inc. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording or any information storage or retrieval system, without written permission from the publisher. CONCRETE CONTRACTOR (USPS 021-799, ISSN 1935-1887 (print); ISSN 2471-2302 (online) is published 7 times a year: January, February/March, April/May, June/July, August/September, October/November and December by AC Business Media Inc., 201 N. Main Street, Fort Atkinson, WI 53538. Printed in the U.S.A. Periodicals postage paid at Fort Atkinson, WI, and additional entry offices. POSTMASTER: Send address changes to Concrete Contractor, PO Box 3605 Northbrook, IL 60065-3605 August/September 2018, Issue 5, Volume 18 One year subscription to non-qualified 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. Printed in the U.S.A.
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4 Concrete Contractor | August/September 2018 | www.forconstructionpros.com/concrete
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Ryan Olson, (800) 538-5544, ext. 1306 rolson@ACBusinessMedia.com Kim Basham, Jim Baty, Brad Humphrey, David C. Whitlock, Joe Nasvik, Chad White Cindy Rusch April Van Etten Wendy Chady Angela Franks
Concrete Contractor is the Official Media Sponsor of the CFA Foundation Company Certification Program
®
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Repair and strengthen all in one shot. Repair, protect and strengthen aging, damaged or overloaded concrete and masonry structures in one application and significantly reduce your installed cost. The new FRCM Externally Bonded Composite Strengthening System combines high-performance sprayable mortar with carbon fiber mesh to create thin-walled, reinforced concrete shells without adding significant weight or mass to the structure. To learn more visit go.strongtie.com/frcm or call (800) 999-5099. ForConstructionPros.com/10074628 Š 2018 Simpson
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Strong-Tie Company Inc. FRCM17C
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LEGAL MATTERS
Social Media
David C. Whitlock has over 25 year’s experience in business immigration, compliance, employment counseling and training. He is the founding attorney of Whitlock Law LLC and can be reached at (404) 626-7011 or at davidcwhitlock@gmail.com.
Should contractors implement a social media policy?
A
s more younger people enter the labor pool, and as technology increases daily, more workers turn to social media outlets for news, entertainment and networking. Social media posts can be good and bad. On the one hand, “good” social media can help your business, as word about your company, workers or quality of work spreads among the industry or public. On the other hand, “bad” social media can really hurt your business as customers, or worse, employees, complain in a public forum about your company or its practices. Concrete contractors are not exempt. Too often, the immediate response to employee posts is to try to shut them down, and if that fails, discipline or terminate the employee. This can be a very dangerous practice. The National Labor Relations Act, or NLRA, is a federal law that regulates how workers are treated by employers and how they can be represented by collective bargaining agents. The NLRA applies to almost all concrete contractors, whether unionized or not. The law is administered by the National Labor Relations Board, or NLRB, which consists of five members who serve staggered terms and are appointed by the President and confirmed by the Senate. This process means that the composition of the Board roughly follows political change in the White House and Congress. Section 7 of the NLRA protects an employee’s right to choose a collective bargaining representative and to engage in “protected concerted activity.” Employee activity is
“protected” if it relates to terms and conditions of employment; it is “concerted” activity if the employee is acting for the benefit or on behalf of others, and not merely for his or her personal interests. An employer cannot interfere with, restrain or coerce workers exercising their Section 7 rights. In recent years, the Board has taken a very liberal view of employee activity, particularly with respect to social media. While that is slowly changing now that the Board has a Republican majority, concrete contractors still need to beware of precipitous reprisals against employees who post negative comments on social media outlets. For many years, the Board held that employer rules that are vague, ambiguous or overbroad and could be construed as restricting employees’ Section 7 rights were unenforceable under the NLRA. Essentially, the Board adopted a test that looks at the explicit language of the rule or policy; if it expressly restricts Section 7 activities, it is unlawful. Even where the rule or policy does not explicitly restrict employee rights, it will still be found to be unlawful if: • It can reasonably be construed to restrict Section 7 rights. • It was created in response to union activity. • It has actually been applied against Section 7 rights. This test comes from a 2004 NLRB case commonly called Lutheran Heritage. Last December, however, the Board abandoned this test. Now, the Board will look at a facially neutral rule or policy to determine the balance between the NLRA’s rules and the employer’s legitimate, business justification for the rule or
policy. The Board identified three categories of rules that would result from this new balancing test: • Rules that are facially lawful because either there is no adverse impact on NLRA rights or any impact is outweighed by the employer’s justifications. • Rules that require individualized scrutiny to determine adverse impact and business justification; and • Rules that are facially unlawful because they directly affect NLRA rights with insufficient business justification. The Board ruled that most employer “civility” rules fall under the first category, but that rules prohibiting discussion of wages and/or benefits or other terms and conditions of employment fall under the last category. So, what does all this mean to concrete contractors? If you adopt a social media policy, try to make it as specific as possible and include the business reasons for the rule or policy. If you choose not to adopt a formal policy, be very careful about social media posts. Your treatment of employees should never be construed as limiting their rights to talk or “gripe” about work. Instead, you should try to be open and communicate with all employees to express your commitment to their well-being. You can try to get disgruntled employees to agree to rescind adverse posts, but be very careful about threatening discipline. If social media becomes particularly adverse, you might consider hiring a public relations company to combat the negative image. If nothing else, a good vendor will help you put out the “good” word about your business.
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N O R T H R O C K
I N D U S T R I E S ,
I N C .
CONCRETE VIBRATORS
“Built to last” Electric Concrete Vibrator
2-Stroke Backpack Vibrator
Whether the job is a curb or a 60’ column, Northrock has the vibrator to get it done!
4-Stroke Backpack Vibrator
Phone 800-989-8423 · 631-924-6130 Fax 800-315-1277 · 631-924-6369 www.northrockindustries.com Info@northrockindustries.com ForConstructionPros.com/10074046
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NEW PRODUCTS
New Products ››››› A compliation of the latest products to the concrete industry.
Proline’s End Grain Edgeliner
The “finishing touch” is what the End Grain Edgeliner will add to a wood plank, stamped patio or concrete counter top. Combine Proline’s wood textures with Proline’s End Grain Edgeliner and surprise everyone when they find out it’s concrete. Edgeliners and stepliners should be an essential part of decorative stamping and Proline offers a variety of textures that will work with any stamp you choose! ForConstructionPros.com/12299469
Hilti Connect App
Tool information, service history and more are now available on your smartphone or tablet using the The Hilti Connect app and NFC tag inside the tool. • Easily identify the tool and access all its unique information even when the serial number is unreadable
• Displays last repair time, how many times a tool has been repaired and total amount spent • Initiate repair scheduling at the touch of a button • Track tool usage information for the DX 5 and DX 9 direct fastening tools • Provides access to how-to videos, operating instructions and OSHA silica dust standards by tool type ForConstructionPros.com/21009880
BonWay Decorative Concrete Border Kits and Mat Set
The BonWay division of Bon Tool Co. has expanded its decorative concrete product line with four new Decorative Concrete Border Kits and a 4-piece Border Stamp Set. These new border imprinting tools provide alternatives to the urethane border mats already available from Bon. • The Border Kits each include a Stamping Roller and a matching Border Mat to quickly and easily install patterned borders. • The rollers are 8” or 9” wide and offer a simple way to incorporated linear features to decorative concrete jobs and provide a custom look even for curved areas. • With the rollers, borders can be rolled out by one person, saving time and money. • Four border patterns are available: 8” Cut Slate; 8” Worn Brick; 9” Old World Soldier; 9” Old Stone Tile. ForConstructionPros.com/21011234
Diamond Products CC7574DD
The CC7574DD allows for increased production, lower maintenance costs and better fuel efficiency than other saws in its class. The Tier 4 Final diesel engine also has high pressure common rail electronic fuel injection. The computer interface control panel notifies you of important information while the saw is running. ForConstructionPros.com/21007190
Bobcat Rear Camera Kit
The optional Rear Camera Kit for M-Series and newer Bobcat skid-steer and compact track loaders provides a continuous rear view of the machine to prevent contact with obstacles. • Includes a 4.3-in. LCD color monitor with a LED backlit screen, wiring harness, mounts and a tailgate-mounted camera • Camera provides a 118° horizontal viewing angle and an 89° vertical viewing angle • Multiple screen and camera settings enhance display image for optimal viewing in both light and dark conditions • Shock and vibration resistant. ForConstructionPros.com/21009876
TEC FILM Topical Evaporation Control from Butterfield Color
Butterfield Color is happy to introduce TEC Film Topical Evaporation Control, the latest addition to our expanding line of decorative concrete products. Topical evaporation control is recommended in all applications where a superior finish is required on concrete flatwork. It protects concrete from the effects of excessive moisture loss in rapid drying conditions such as low humidity, elevated temperatures or brisk winds. It is also effective in reducing surface cracking at the edges of grout lines when stamping concrete. It is packaged in both a 3 lb. concentrate and a 5 gallon Ready to Use pail. ForConstructionPros.com/20996839
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Introducing the world’s most comfortable safety toe. Rocky brings you the industry’s first ASTM certified externally attached protective toe. The Rocky XO-Toe’s innovative external composite toe guard gives your toes space without compromising safety. Designed for all-day comfort and performance with lightweight construction and our Rocky Rebound cushioning midsole, you may just forget you’re wearing a safety toe. Rugged safety never felt so good.
ForConstructionPros.com/10163168
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NEW PRODUCTS Makita's New XSR01Z is the First Cordless 7 1/ 4-in. Circular Saw
At World of Concrete 2017 Makita announced the new 18V X2 LXT Lithium Ion (36V) Brushless Cordless Rear Handle 7- 1/4-in. Circular Saw, model XSR01Z. It is the world’s first cordless rear-handle 7-1/4-in. circular saw powered by two 18V lithium-ion batteries. The new saw will be available in spring 2017. “For users of corded blade-left rear-handle saws, the new XSR01Z offers true freedom from the cord for formwork, framing and more,” said Andrew Camp, Product Manager, Makita USA. “The XSR01Z cuts faster than both corded and leading brushless cordless saws when cutting 2x10 SPF. In early testing this cordless saw put up big numbers in run-time tests with up to 558 cross cuts of 2x4 SPF and up to 291 cross cuts of 2x10 SPF with two fully-charged 18V LXT 5.0 amp-hour batteries. With a full 2-9/16” maximum cutting depth the XSR01Z cuts 3x lumber in a single pass.” The new XSR01Z is part of Makita’s continuing drive to address the demands of pro users. Makita continues to expand the LXT system with more cordless options including dust management and a ‘world’s first’ for formwork with the new 18V X2 LXT Lithium Ion Brushless Rear Handle 7-1/4" Circular Saw.” ForConstructionPros.com/12295652
Buddy Rhodes Color Wheel
Now available is the new Buddy Rhodes Color Wheel with over 400 Concrete Pigments. The Buddy Rhodes Color Wheel features three distinct color collections. • The Buddy Rhodes Specialty Collection: Based on the popular Benjamin Moore paint library, the BR Specialty Collection features more than 400 pigment options. • The Buddy Rhodes Signature Collection: 15 timeless colors, hand selected by Buddy Rhodes. These colors all feature the same convenient dosage; add 1 lb. of BR Signature pigment to one bag of any BR Blended Bag Mix for perfect color every time. • The Buddy Rhodes Pure Collection: Use straight or mix together to create your own custom blends. The company offers 24 vibrant pure pigments to suit any taste and style. ForConstructionPros.com/21015242
Trimble Spectra Precision LT52G and LT58G Green Beam Lasers Dust Collection Products New Dual Purpose 220 CFM HEPA Vac System
Dust Collection Products now offers a 220 CFM HEPA vacuum system that can be split into two individual 110 vacuum systems when needed. • The system comes with all the fittings needed to combine the two 110 CFM vacuums into a robust 220 CFM system. • It can be reconfigured in less than a minute to give the contractor two individual 110 systems that can be sent to separate jobsites. • It comes with 20 replaceable filter bags and 35’ of 1 ½” hose. ForConstructionPros.com/21013778
The LT52G and LT58G automatic selfleveling lasers feature high-visibility green laser beams suited for interior conditions with bright ambient lighting. The LT52G is both a five-beam laser pointer and a horizontal and vertical crossline laser that can be used for tasks such as wall layout, horizontal and vertical leveling and 90° squaring. The LT58G projects three 360° planes of ultra-bright green laser light. Its horizontal plane is intersected by two vertical planes. ForConstructionPros. com/21014231
W. R. MEADOWS DECRA-SEAL NATURAL
New from W. R. MEADOWS comes DECRA-SEAL NATURAL, water-based sealer that enhances the natural appearance of a variety of decorative hardscapes. DECRA-SEAL NATURAL can effectively be used on interior, exterior, horizontal and vertical decorative concrete, pavers, unglazed tiles, and a variety of porous natural and artificial stones. DECRASEAL NATURAL is a non film forming, penetrating water repellent that chemically bonds to the substrate to help increase the service life. DECRA-SEAL NATURAL offers a long-lasting, non-yellowing matte finish while also offering excellent sealing benefits. ForConstructionPros.com/21012730
Vexcon Announces New Fast Drying Penetrating Water Repellent Sealer
CERTI-VEX PENSEAL 244 FD is a high performance, breathable fast drying clear silane water repellent penetrating sealer. The product is ideal for cool weather applications and where dry time is critical for fast return to service. Certi-Vex Penseal 244 FD stops the intrusion of water, salts, deicer chemicals, and acids, which often result in efflorescence, mildew growth, corrosion, scaling, spalling, surface erosion, and other costly damage to hard surfaces. Treatment of reinforced concrete reduces surface erosion and corrosion of rebar caused by attack of water and water borne salts and alkalis. Benefits: • Extends the life of concrete and masonry • Long term protection against salt corrosion, mildew, water, wind driven rain, airborne contaminants, surface spalling and other extreme weather conditions wwForConstructionPros.com/21007432
10 Concrete Contractor | August/September 2018 | www.forconstructionpros.com/concrete
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HUMMER VIBRATORS DELIVER MORE
AMPLITUDE
Multivibe Hummer line of portable concrete vibrators have the highest amplitude for better consolidation, and the largest selection to meet any jobsite application. We offer models for deep foundations, standard walls, ICF pours and shallow slabs. Choose from standard or fishing pole vibrators powered by Honda. Heads from 1 inch to 2 ½ inches with casings up to 24 ft. lengths; All with low friction cool heads that won’t burn up outside of concrete. Hummer vibrators get the job done.
Mfg. By
Jlin Corp.
3125 N. Friendship Rd. Paducah, KY 42001
Quality ForConstructionPros.com/10073475
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TOLL FREE 1.877.220.6652 PHONE: 1.270.554.2615 FAX: 1.270.554.0631
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FLATWORK/ SLABS
By Chad S. White
Figure 1: On site steel fiber loading station. Photo Credit: Chad S. White
Placing Concrete
SMARTER: A Closer Look Part 2
Part two of a of three part series. This feature will take a more in depth look at productivity and quality variables for common slab on grade installations.
P
lacement Lay-Outs will be dictated by overall sequencing of project construction and key milestones in the schedule. Try to maintain uniformity
in placement size and configuration. How the end user will be using the floor should be considered when determining joint lay-out, (racking, dock areas, high traffic areas, show room). Try to avoid long, narrow placements to minimize curling potential. Reducing construction joints across aisles should be a key focus along with flatness specifications.
SITE ACCESS & LOGISTICS Travel routes and staging areas to a large degree must be built into the overall constructability of the building. You must have input at the earliest stages of the project
to insure adequate access for slab placements. If you are just doing the slabs those decisions will often times be made before you ever show up. Travel routes will require occasional maintenance, flagging and adequate lighting. One way routing of concrete trucks is preferable if site conditions allow. Staging areas are required to position and prepare concrete trucks for discharge, wash-out, concrete testing and the on-site addition of admixtures or fibers. Typically concrete trucks are prepped and tested as close to slab placement as possible without hindering traffic flow. Access for personnel and
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Figure 4: Laser screed strike-off and check rod. Photo Credit: Chad S. White
equipment to two sides of placement is preferable. Lighting – How much is enough? OSHA requirements, contract language and specifications will establish minimum foot candle illumination requirements but it is really much simpler. You can’t finish what you can’t see. Safety is the prime consideration in planning area lighting on a construction site. Keep in mind that minimum lighting will impact production rates.
• Sub-base proof-rolled and elevation confirmed. • Insure that all work by other trades is complete and location/ elevation verified. • Reinforcement, at least 80% complete provided that the installation of the balance doesn’t impact concrete placement. • Vapor barriers in place, lapped and edges taped. • Expansion joint material installed. daily placing of concrete. Concrete placements should be forecast and scheduled weekly and go/no go decisions made at least eight hours ahead of placement start time. During the placement there must be open communication between batch plant, concrete crew lead, QC and testing. Pertinent data to communicate should include start time, slump, temperature and delivery rates. Concrete service should be matched to place/screeding method and crew capabilities.
PLACING & SCREEDING METHODS
Figure 2: Base compacted, columns wrapped. Photo Credit: Chad S. White
Figure 3: Base rutting to be repaired during placement. Photo Credit: Chad S. White
Break areas and bathroom facilities should be easily accessible to all personnel involved with the slab placement.
SLAB PREPARATION BEFORE PLACEMENT In an ideal world every placement would be 100% ready, inspected and signed off before concrete is released. The reality of access and pending weather events necessitates a little more flexibility. The first step is prioritizing what work must be complete before placement starts and what can be successfully completed while the placement is ongoing. Before releasing concrete these are the some of the items that definitely need to be complete; • Edge forms and block-outs installed to grade and braced.
During the concrete placement; • Touch up grading and compaction of sub-base. • Monitoring and adjusting formwork elevation and straightness. • End of placement bulkhead. • Chairing of rebar and installation of dowel baskets. • Slip sheets non taped. • Protective wrapping of columns, walls and work in place. Pre-Placement Checklist and Sign Off if used correctly is a powerful tool. It requires accountability and provides a job site record.
CONCRETE SERVICE AND PLACE/FINISH CAPABILITIES Scheduling, rapid communication between all pertinent parties and fall back options play a huge part in the
Discharging directly from concrete trucks is the most efficient means of delivering concrete to the point of placement provided there is adequate access. Pumps, conveyors and buggies are used when site conditions, placement reinforcement or embedded items preclude truck dumping. Pumping is the preferred alternate due to widespread availability and placing options. Conveyors have the advantage of being able to place mixes too harsh to pump and high volume production rates. Georgia Buggies were in use when I started over forty years ago and still have their place on the job site for placements of 50 cubic yards or less. Placing and screeding methods selected will impact slab configuration and access required. Slab placement width to a large degree will determine strike-off methods. Form to form screeding such as truss or roller screeds are seldom wider than one bay or 50’. Wet screeding by hand or machine will be limited by set time of the leading edge of
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FLATWORK/ SLABS the concrete placement. Typically wet screed placements will have a maximum width of 150’. Screeding method employed will be dictated by flatness requirements, placement width and equipment availability. Screeding methods can be basically be broken down into (3) distinct types; • Mechanical, automated laser controlled screeds. • Form to form mechanical vibrating or roller screeds • Hand controlled wet screeding utilizing non-mechanical straightedge or powered vibrating straightedge.
Figure 5: Light burnish, plastic trowel blades.Photo Credit: Chad S. White
GETTING THE FINISH RIGHT Burnish & flatness – The days of just running a trowel machine over the slab until it turns blue are over. You need to understand the burnish requirement for the slab. Exposed slabs will often have different burnish requirements than polished or covered. Carbon steel trowel blades are great for producing highly burnished floors but have the potential to scratch the surface and leave the surface too dense for satisfactory polishing. Plastic trowel blades are much more forgiving and do not mark-off or scratch the surface as easily. It is my opinion that except for rare situations bump cutting of the surface behind trowel machines should be eliminated. Bump cutting of floor will negatively impact cosmetic appearance of floor slab with increased aggregate
shadowing and pin holes. Modern strike-off methods and floor panning techniques will consistently achieve FF60/FL40 floor flatness numbers without bump cutting. The quality of slab edge finish and attention to detail defines a great slab placement. The goal is to blend slab edge burnish, levelness and cosmetic appearance with the main slab. Machine floating/ troweling techniques, power edge trowels and team craftsmanship make the difference.
AMBIENT WEATHER CONDITIONS AND WEATHER PROTECTION FOR CONCRETE PLACEMENTS Concrete mix designs are expected to conform to various protocols in regards to temperatures variances and without getting technical that is 50-90 degrees for fresh concrete. The differential between concrete and ambient/base temperatures should be 30 degrees maximum, twenty degrees preferred. Methods to modify concrete placement set and finish: • Slump • Concrete temperature • Admixtures • Environment Slab shrinkage and damage during construction phase due to site conditions and sequencing should be understood by all. Costs to modify concrete mix, site conditions or other for hot or cold weather conditions should be discussed and agreed upon by all pertinent parties.
MIX DESIGN SET CHARACTERISTICS AND FINISHABILITY Mix designs are formulated by Ready-Mix producers to project specifications and approved by the Engineer of Record. The ability to place and finish the proposed mix are usually secondary concerns and set times are seldom discussed. It is the responsibility of the place/finish contractor to understand the mix design being placed. Placeability will have an impact on the method of placement chosen. The ability to spread, strike-off
and finish should be the primary consideration when reviewing mix designs and test panels by the field crews. You should strive for a uniform fluid mix design that holds together, displays minimum bleed water, seals up at the specified slump and sets within a satisfactory time frame. Pumpability may or may not be a factor for slab on grade placements but it is important to remember that many of today’s mix designs for slab on grade are difficult to pump due to top side aggregate size, cement content and the addition of fibers. It is recommended that if an alternate mix design is required to insure pumpability that it is approved prior to intended use. Finishability - The basic non-environmental factors that affect finishability at the field level are; • Sufficient cement paste to provide acceptable burnish and finish using conventional equipment. • Coarse aggregate gradation and content will affect mix design workability and amount of bleed water at the concrete surface. Natural sand or manufactured? Acceptable finishes can be achieved with either but normally natural sand is preferred due to sand particle shape being easier to finish. • Fibers are the greatest thing since sliced bread although the practice dates back to putting horse hair in plaster. The use of fibers does impact the surface cosmetics. • Admixtures – Keep it simple. I’m not an expert but I am enough of a cook to know that the more ingredients in the recipe the harder it is to execute properly. • Uniformity of placement and slump control. Slabs finish the way they are placed. There is many options available for designing a concrete mix design. Slab on grade mixes are designed to reduce or mitigate slab shrinkage and movement. Placing concrete smarter pays off in safety, quality and productivity gains.
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FOUNDATION & WALLS
By Joe Nasvik
Using MIXED REALITY TECHNOLOGY in Construction Mixing reality and virtual reality in 3D.
I
n 2015 the Microsoft Corporation introduced “HoloLens™,” 3D holographic hardware and software that makes it possible to view objects that aren’t real with scenes that are real. The technology is referred to as “mixed reality” (MR) or “augmented reality” (AR). Eric Harris, a Strategic Communications Manager for Trimble, says MR and
AR permit you to see something that isn’t there overlaid on something that is real. But technically there are some differences between the two, MR inserts virtual objects into a real world while AR inserts data and some types of graphics, and example being the backup camera on your car which overlays lines and sometimes numbers into the live action video screen to help you know where you are. Neither MR nor AR should be mistaken with virtual reality (VR) which doesn’t include the real world in what you see.
Using Microsoft HoloLens technology, manufacturers serving the construction industry are beginning to provide contractors with holographic 3D images what help them understand their work tasks better. Photo Credit: PERI Formwork Systems
Microsoft markets their MR equipment and software to the computer gaming industry but it is also interested in developing technology with third party vendors. This article is about two such companies that are using Microsoft MR to provide new technology that benefits
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ST
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FOUNDATION & WALLS the construction industry; Trimble, based in Sunnyvale, Calif., and Peri Formwork Systems USA with US headquarters located in Elkridge, Md.
TRIMBLE Trimble is a US company with a worldwide reach. It is well known to the construction industry for its surveying equipment technology, 3D modeling software, GPS surveying, and machine control technology. They focus on cutting edge technology that now includes being able to see virtual holographic construction objects overlaid onto the location they will be installed on a project. To accomplish this Trimble developed
also part of the assembly and it helps the HoloLens to know its position. A microphone is also included. The camera photographs what is in front of you and picks up signals from your fingers to navigate menus and commands. HoloLens presents its best images in lower ambient lighting conditions. BIM. Construction projects increasingly use Building Information Modeling (BIM) design software. BIM combines 3D models with powerful databases that project participants add their information to. MR can utilize many 3D design programs but BIM is the most popular one on construction projects and contractors on larger projects often hire full time
a software applicaBIM specialists to Using the HoloLens mounted to a tion for Microsoft’s keep the drawings up hardhat and Trimble Connect for HoloLens the persons shown here HoloLens called to date. When jobsite are able to compare what has been “Trimble Connect personnel turn on installed to a 3D holograph of the for HoloLens” as well their HoloLens BIM BIM drawing details. as an attachment graphic images Photo Credit: Trimble accessory to attach become the 3D the HoloLens to a hardhat for use hologram that fits seamlessly into the on a construction site. The plastic real scene in front of the wearer. For outer lens of the unit acts as safety example, if you wish to see what the glasses and is tinted to reduce bright rebar would be like on a location you ambient light. Inside the visor is what would look at the space (which the looks like glasses and that’s where camera in the HoloLens photographs) you see the holographic images. and choose the BIM detail showing The band holding the device to your the rebar placement. The holograph head (and to your hardhat) also conshows what the rebar placement tains a computer. A camera which would look like, allowing the user to maps the environment around it is view it from any angle.
Trimble Connect. Architects and designers typically work on 3D project drawings and details in their offices. Then they publish them on Trimble Connect, a construction collaboration platform, to give all project participants who have permission to see them, providing them with the opportunity to add their parts and interact with each other. Trimble Connect for HoloLens becomes the platform that enables participant access through their HoloLens device. Trimble Connect software can view drawings from a variety of different software programs and it supports viewing on several devices including desktop computers, tablets, cell phones, and HoloLens. Users. Any number of people can be given permission to use Trimble Connect to access plans for a job but David Burczyk, the Segment Manager-Field Technology Group at Trimble thinks contractors today will primarily focus on HoloLens technology for quality control, craftworker training, and safety. Important benefits. The construction world is headed in the direction of paperless design, one advantage being that changes to a plan can be continuously updated so that everyone sees the most up-to-date information. Foremen who are responsible for setting concrete forms or iron workers who install rebar reinforcement for example, can be located where the work is installed, easily visualizing what they must do. Burczyk says you can view the 3D model on a mobile phone or tablet in Trimble Connect. However the benefit of the HoloLens application allows you to interact and be immersed in the model at full scale on the project site, viewing it from different angles. It’s easier to understand things three dimensionally. When work is installed a foreman can quickly check it against the BIM holograph to be sure their work is installed properly. If something is not right it is quickly identified. Burczyk says project managers can check work too. For example, a floor on a
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FOUNDATION & WALLS building that has rebar, post-tension reinforcement, rough plumbing and electrical, and imbeds can be compared through the HoloLens to the model. If something is wrong Trimble Connect makes it possible for the viewer to connect with persons in their office to decide what to do, office personnel can see through the HoloLens to view what the person on location is seeing. In this way problem areas can quickly be discovered and reworked. These checks can become part of the construction log for a project too; assuring that work was installed properly before concrete placement. Looking at the system. Ryan Barker, manager of virtual design for Wayne Brothers Incorporated, Davidson, N.C., says they are currently using cellphones and tablets to connect via Trimble Connect to access BIM drawings but they are studying the feasibility
of using Trimble’s new hardhat HoloLens technology.
PERI When a contractor is estimating a project where concrete forming is a significant part of the work, their first call is often to a formwork
manufacturer to set up a meeting to figure out the best technology to use. Contractor’s productivity is frequently related to their choice of a forming system so there is much discussion and learning that takes place as forming technology keeps changing and improving. So the
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Shown here is a 3D BIM drawing of a rebar detail, it becomes the virtual part of the mixed reality view seen through a Holographic holograph.
manufacturer often becomes a trusted partner in a construction project. But the manufacturer may be the one Photo Credit: to initiate the Trimble partnership, PERI Formwork Systems US, based in Elkridge, Md. regularly partners with contractors who are bidding a project and presents their technology in hopes the winning bidder will use their system. To help contractors and owners representatives visualize their innovative solutions, PERI utilizes software to help clients visualize how their advanced forming systems work. They use a gaming tool program language called “Unity” to create an MR format that can be viewed by several 3D drawing programs such as SketchUp,
AutoDesk, and their own drawing program PERICAD. How it works. MR means that part of a scene is real and part isn’t real. The real part is the physical environment and the virtual part is the 3D model of structure with PERI’s forming system. Program software scales the 3D formwork model to fit on a conference table or view in full 1:1 scale. Mark Henning, PERI’s Director of Markets and Products says they can take this technology into the field and enable contractors to see the formwork model in place on the job-site. Clients view these formwork solutions in either 2D or 3D depending on whether computer monitors, tablets, or Trimble Connect for HoloLens technology is used to help them understand how their forming system works. Contractor benefits. During the estimating phase of a project PERI uses their models to present their
advanced forming solutions such as their self-rising perimeter protection system or core-forming systems and how they work. If a construction site requires elaborate concrete forming they can also show contractors and crews the safest and most efficient way to assemble their forms. By using MR technology, and their workers can virtually construct and visualize the formwork ahead of time in order to streamline the actual assembly, installation, and cycling process.
CLOSING THOUGHTS The world of construction continues to move in the direction of collaborative activity and at the same time it becomes more demanding and technical. Programs building on MR help us understand the details and be sure that everything is accounted for. Continuous learning is our future at a time when change is constant.
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COVER STORY
By Adrian Rojas and Myron Hillock
Against All
›››› ODDS How the Mega Slab Became a Success
E
ven for mid-January, it was unseasonably cold in Texas. Normally the temperatures get close to 60-degrees Fahrenheit during the day, but for team members at the GM plant in Arlington who were ready to embark on a historic event, seeing your breath at noon wasn’t out of the question. The bad luck in weather served as just a microcosm of the several challenges Barton Malow and its partners, Lloyd Concrete Services, Unlimited Concrete Solutions, Redi-Mix, Multiquip, Somero Enterprises, Transhield, Bekaert, Allen, Wacker Nueson, Husqvarna and many more, faced and overcame as they took on one of the largest continuous
concrete pours ever conducted in the region. As the story unfolded, planning became a crucial element in ensuring the project was not only done, but done well.
PLANNING Placing 256,000+ square feet of concrete isn’t just something you can do on a whim. It took 33 continuous hours start to finish, dozens of equipment pieces, materials and more required extensive planning and expertise. Oh, and not to mention the 140 tradesmen who were flown in from across the country by Barton Malow. “We build virtually before boots even hit the ground,” says Barton Malow Superintendent Brian Willard. The company’s Virtual Design & Construction (VDC) team shouldered the responsibility of providing an interactive model for the
Mega Slab event. Jason Neff, VDC Manager, led the charge. He created a 4D model that combined what the project would look like down to the minute; it featured 2,280 parts. How did it help? By seeing what the project could look like—again, down to the minute—the team was able to determine timing, equipment and budgeting. Most importantly, however, the model also gave the team confidence. “The intangible of knowing that a project can succeed because you’ve seen it run virtually is underrated,” says Barton Malow’s Ethan Uhl, Placement and Finishing Superintendent. When even minutes can make a crucial difference in a project as complex as the Mega Slab, the model also served as a way to discover mishaps that could happen—before they happen. “We had to ask ourselves, ‘What could go
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wrong?’,” says Willard. Contingency plans were drafted for those ‘ just in case’ scenarios. These simple measures led to increased work flow and made sure the team stayed on plan. “To the average person, these actions are probably things that people don’t think about. But every little detail needs to be perfect for a project like this,” exclaims Willard.
Tradesmen from Barton Malow, Lloyd Concrete Services, Unlimited Concrete Solutions and partners pose prior to embarking on the epic Mega Slab project. Photo Credit: Barton Malow
for a large portion of the placement. In the end, the team averaged 315 cubic yards per hour. “We just lined the mixing trucks up and let ‘em rip,” says Willard. Planning the roles of the people behind the project was just as thought-out. The goal was to maximize their skills without wearing them down. Through rotating shifts, project leaders EXECUTION did just that. With the Tradesmen plan in hand, were split into the crew knew several teams they had to be with assigned as close to exact colors to make it as possible. But as easier to identify. is the case with most Two teams started undertakings this big, it placement with the came with its own set second team starting A Barton Malow finisher of hurdles. The original slightly behind the first proudly hand trowels plan was to dump a to give them physical concrete for the Mega Slab. ready-mix truck once room to operate Photo Credit: Barton Malow every 90 seconds. But properly. Three more when some of the mixing plants teams arrived at the 11th hour of the had technical issues and backproject, which replaced the original ups needed to be called, the pace two that arrived at the beginning. slowed. For the first crucial hours of At the 23rd hour, and after some rest the project, things weren’t perfect. and food, the original two teams But when the back-up plants started were shuttled back to relieve their firing and the others came back into replacements and complete the action, concrete trucks arrived en finishing of the slab, saw cut and masse toward the site, and a pace of water cure process. 550 cubic yards per hour was held The amount of concrete used in this project was astronomical. It necessitated five batch plants—all suppliers coming from the same source to ensure material consistency—working overnight. But the potential for freezing became an issue. Getting salt and heaters was a priority, so the team stockpiled necessary materials weeks in advance. In addition, they moved the steel fibers on site as to ensure cold weather had little-to-no impact. Lasers were installed every 150 feet with thorough testing to every screed to ensure consistent leveling. Crews begin placing the concrete for the Mega Slab. Photo Credit: Barton Malow
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COVER STORY
are driving across Tradesmen the site, you can’t commence the 8 inch thick, really ask for much 256,000 sq. ft., better results. steel fiber GM When it was project. all said and done Photo Credit: Barton Malow after 33 hours, 6,470 cubic yards of 8-inch steel fiber reinforced concrete were placed in what was one of the largest continuous projects of its kind.
BUILD IT SAFE
Four Somero Laser Screeds® ran non-stop during the 20.5 hour placement. Photo Credit: Barton Malow
“The meticulous setup of the five lasers is the best I have ever seen on a multiple laser pour” comments Somero’s Derek Ryan. Quality - some concrete professionals might say a Floor Flatness (FF)/Floor Levelness (FL) of 56/42 is “just okay.” But
when one considers the sheer size of the project, production rates, the number of bodies, equipment, vehicles and materials on the ground, it becomes clear just how exceptional that number is. Moreover, the fact that the civil crew got grade within 3/16th of an inch across the placement’s square footage meant concrete yield stayed within 2% of the plan. When 647 concrete trucks
Barton Malow’s motto behind every project is Build It Safe. A 256,000-sf concrete placement is no different. Thorough pre-task plans were created by safety leaders and then effectively communicated to the crew. During the Mega Slab orientation at the hotel, everybody discussed plans in detail. Rescue plans and evacuation routes were established and shared with not only the tradesmen, but security at the GM Arlington Plant to maximize efficiency. On-site nurses were provided from the beginning to end of placement, in addition to hydration and break stations set-up near the pour.
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COVER STORY
Quality of life and safety of the team was also a primary concern. Due to the cold temperatures proper ventilation was a concern. Air handling units capable of exchanging 9-million cubic feet of air per hour were installed before work began and air monitors were used throughout the project.
TEAMING – WHO WAS INVOLVED? A project as big as the Mega Slab wasn’t something that could be done by one entity; it took a collection of groups to get the ball rolling on this endeavor, let alone finishing it successfully.
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35 team memLEFT: A Barton Malow Somero bers from Lloyd Laser Screed Concrete Services, begins another 31 from Unlimited precision pass. Concrete Solutions Photo Credit: Barton Malow and 74 from Barton Malow brought their all to the project. Crew members, most of whom were flown in, stayed at local hotels secured by Barton Malow near the site. They were provided with meals and a shuttle service to take crew members from airport to hotel and hotel to jobsite. “It was really and truly a well-oiled machine on game day,” says Chris Daley, General Manager at Unlimited Concrete Solutions. “The plan was gone through so many times that every part of it was known by all. So, when plan B was needed, quick decisions could be made.” UCS was highlighted by 31 skilled tradesmen, two Somero machines, trowel machines, saws and vacuums. Rustburg, Virginia’s Lloyd Concrete Services also made its mark. They supplied 35 tradesmen, two Somero machines, riding and walk-behind trowels and cut saws. Stevie Ray Lloyd, Vice President of LCS, was impressed by how his tradesmen were treated: “The experience reminded me of a college bowl game. I played Division I football at Virginia Tech, and the way Barton Malow did things were the same as a bowl game.” He continued, “They flew everyone out to Texas, rented an entire hotel near
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the site, provided meetings, meals, hydration stations, nurses and more.” Ask any concrete pro, and they’ll tell you that leveling is everything. The excellent leveling seen at the Mega Slab was led by Somero Enterprises, as their innovative Laser Screed® machines served as the backbone for the project’s consistency. “I remember the initial call from Ethan Uhl,” says Myron Hillock, Sales Director for Somero Enterprises. “He asked me ‘Is this even possible?”’ I assured him it could be, and that they had our support.” During the planning stage, Somero and Barton Malow coordinated several meetings. The plan called for utilizing the contractor’s inventory of four large S-22 Laser Screed® machines and two smaller S-940 units with two S-840 models to serve as backups. Dumping a truck every 90 seconds left no time for wide overlaps and re-screeding a pass was out of the question. Therefore, a smaller S-940 unit was assigned to each pair of S-22 machines to quickly raked the truck dumped concrete close to grade prior to screeding. In addition, Somero’s on-site support staff of Trainer/Operators and support technicians provided continuous screed operation during restroom and refreshment breaks. Somero’s Thad Fritz adds, “This was critical for production because the plan called for 22 hours to place and screed, yet with the slower than planned start we were behind at the midpoint.
But with the ramped up ready-mix delivery and zero downtime on the screed machines, the last truck was dumped and screed pass made at 20 1/2 hours. Over 90 minutes ahead of schedule and under budget.” “We were there to support no matter what the issue would have
ABOVE: The Mega Slab was finished using power trowels. Photo Credit: Barton Malow
MIDDLE: Trowel machines from Allen, Multiquip and Wacker Nueson helped achieve a consistent finish on the Mega Slab. Photo Credit: Barton Malow
CONCRETE CURING COVER
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COVER STORY been, but the efficiency, reliability and quality of the Somero equipment was truly evident as not a breakdown or spare part was utilized,” says Somero technician Zach Mills. Redi-Mix, a supplier of readymixed materials in Dallas/Fort Worth, were instrumental in giving the on-site crew a steady flow of concrete. With active and backup
Bekaert Dramix plants, astute steel fibers are truck drivers and loaded into each premium concrete, of the 647 Redi-Mix trucks. the Mega Slab Photo Credit: would obviously Barton Malow not be possible without them. Multiquip, whose wide array of products serve construction, industrial, telecom and other
industries, provided necessary equipment like back-up trowel machines plus an on-site support team along with an assortment of spare parts to support the Multiquip trowels provided by the three contractors. The conveyor belts and the fibers they loaded into to the concrete were supervised by Bekaert, who supplied four team members to the project. “I was impressed by the sheer size of the task at hand. Our product, the Dramix 3D 65/60 steel fibers, resulted in a great slab,” says Jimm Milligan, Regional Manager of the Midwest for Bekaert. With the Bekaert team present, they closely monitored the fiber loading for proper timing. Rick Smith and his Structural Services, Inc. (SSI) brought concrete solutions, education and testing. They provided crucial engineering data and also monitored building temps in advance of the project. Moreover, they gave the crew onsite support the day of the placement to ensure consistency and quality of the slab. And to top it off (literally), ReliableCure curing blankets provided their unique, non-woven engineered absorbent fabric. Transhield also provided TopCure concrete curing covers. The cover is durable, kept material under it wet and was placed in areas where there was a potential for foot and light equipment traffic. Moreover, with a non-slip; surface it was ideal for a high traffic area such as this. “The precision with which this project was ForConstructionPros.com/10615779
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accomplishment, and I can’t wait for the next opportunity to use our planning and execution abilities to make it happen.” Willard also expanded on the use of Barton Malow’s self-perform team for this undertaking: “By using some of our own skilled trades, we had the resources to meet the demands
of the Mega Slab. Our team’s depth of experience gives us the ability to work on unique projects like this while maintaining the highest levels of quality and safety standards.” Pouring 256,000 sq.ft. of concrete is nothing, according to those who took on the challenge. They’re ready for something even larger.
run really stood out for me,” says Mindy Kruggel, Director of Marketing for Transhield. “We were honored to be a part of such an immense project.”
REFLECTING ON THE PROJECT The Mega Slab provided a unique opportunity for all involved. With so many cooks in the kitchen, many wondered if something like this was possible. But as the teams began to collaborate in the pre-planning stage, it was evident that they were ready to take on the challenge. “Whether it was Barton Malow’s contractor management side or the self-perform side, they were united and treated all of the companies and parties that came together as if they were their own,” says Daley. “Everyone came together,” says Steve Lloyd, President of Lloyd Concrete Services. “Teams were assembled based upon each person’s strengths. The majority of workers had never met their teammate working next to them. There were no attitudes, complaints or anything. Everyone knew their role and they just executed it, thanks much to their ACI Finisher Certifications. Everyone just gave it their all; it was a thing of beauty.” For many, the project served as a major milestone—but the companies involved shouldn’t stop there. Uhl states that “this is by far the best thing that has been done in the 10 years I’ve been doing this, but I can’t say it won’t be topped.” Willard agrees: “I think it was a huge ForConstructionPros.com/10072794
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DECORATIVE CONCRETE
By Greg Udelhofen
Beyond Vertical Concrete Turns Imagination to
REALITY
When art meets concrete, backyard fantasy escapes can be achieved as evident by Josh Russell’s latest pool concrete sculpture project.
W
hen I think of decorative concrete, my first thought is a beautiful acid-stained, Flagstone-stamped concrete patio. This is not an article about a beautiful acid-stained, Flagstone-stamped concrete patio. This is an article about decorative concrete on steroids. Enter Joshua
Russell and his companies, Beyond Vertical Concrete and Creative Environments. Russell has spent the past 10 years developing his distinct decorative approach by sculpting and creating three-dimensional concrete hardscape environments for clients. When he was 13-years-old, Russell helped a relative who poured concrete foundations. At 17, he was running a decorative stamping crew. At 24, he gained experience with concrete pumping. In 2008, Russell entered the world of vertical decorative concrete, but was not impressed with the stamps available at the time, and that’s when he started to sculpt the dimensional details he wanted to create.
THE ART OF VERTICAL CONCRETE Russell generally works with solid foam cores that he shapes with a hotknife tool to create the features of his
A concrete canopy creates a secluded grotto, complete with a waterfall, at one end of the pool. Photo Credit: Beyond Vertical Concrete
projects – from rock walls to mountains with a waterfall. Once carved, he then attaches a wire mesh that will be used to hold the first concrete base coat. After the base coat (skim coat) dries, he then applies a layer of concrete, generally 2-3 inches thick, to the vertical structure, which he will shape and carve the detailed features required to make a rock look like a rock, along with other realistic features that will bring a design to life. “If the project is under 1,200 square feet, I’ll hand mix the concrete I need and just throw the mud up onto the surface (in workable sections),” Russell notes. “Then, I have about a half hour to work with the material to shape and carve the details I want.”
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With larger projects (1,000-2,000 square feet), Russell uses a Carousel pulmonary pump to place the concrete on the vertical backdrop. For projects over 2,000 square feet, he moves to a shotcrete application.
GROWING THE BUSINESS TO A GLOBAL MARKET While Russell is currently anchored in Byron, Mich., he travels around the United States and the world for that matter to work on unique vertical concrete projects. “In the early years I used home improvement shows to market my service and the designs I could create,” he states. “But for the past five years all my work has come through referrals from customers.”
feel of the entire space.” Whether it’s designing and creating a unique bar/entertainment space in a client’s basement or a unique outdoor oasis, Russell makes a point to deliver a final product that reflects the owner’s interests and tastes. A current project Russell just completed evolved over the nine weeks it took to complete. That’s
not uncommon, as Russell notes that most projects have added features by the time he completes them. The organic mountain grotto designed to enclose one end of a pool that he just finished included several added features as construction progressed. Using solid foam core to create the cavern, which will include a rain curtain off the front edge
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Russell and his crew are also known for creating unique bar environments. Photo Credit: Beyond Vertical Concrete
In between large projects, Russell and his crew of three create basement bar environments for clients wanting unique designs and features. “We do incorporate some pretty unique concrete features and details on these projects, but the key is tying that unique bar space in with the rest of the space,” Russell says. “The transition from one to the other is very important in the final look and
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DECORATIVE CONCRETE
Russell uses a mortar sprayer to transform the foam shapes into a rock canopy over the pool. Photo Credit: Beyond Vertical Concrete
of the overhang, Solid foam blocks are used to create is the primary the support focal point of the and shape of backyard retreat. the concrete sculptures around Other features the pool. include a sitting wall, cantilevered seating Photo Credit: Beyond Vertical area and a fire pit Concrete located in the beach area behind the wall of the retreat. “We used 38,000 pounds of concrete to create this project (not including the concrete required for the new pool) to create all the vertical features,” Russell says. “We sprayed three inches (thick) of concrete over the features we created out of solid foam and then had about an hour to hour and half to carve and shape the designs. In that time, we completed about 95 percent of the initial shaping and carving and then had about three hours to finish and final carving.” After the concrete cured, Russell sprayed the sculpted concrete
features with colored exterior latex paint (four-parts latex paint to onepart water mixture) to achieve the color finish and seal the surface. “I apply four coats of the matte latex paint to protect the concrete and achieve the color saturation
I want,” Russell says. “I like using Modern Masters, which has a highly concentrated pigment that produces a true long-lasting color finish, but I can only do that when it’s in the client’s budget.” With all projects, Russell
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DECORATIVE CONCRETE The final concrete feature includes a tree root embedded in the rocks. Photo Credit: Beyond Vertical Concrete
promotes a maintenance service to inspect the project every three to four years to see if it needs a new coat of finish to restore the color. Since most of the projects involve several added features after Russell and his crew begin, original project estimates and added change orders are determined based on labor cost. “I know the cost of any given project is going to be 70 percent labor and 30 percent materials,” he says. “So, on this project, the original work we were contracted to delivered included three days to shape and install all the solid
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foam backing, two days to apply the scratch coat of concrete, four days to apply and carve the primary concrete coat, and a day to spray the color finish. An additional 25 percent was added to the final cost based on the additional features the client wanted.” The added features often come when clients begin to see how the project shapes and features start to look when the foam is cut and put into place. “When they start seeing what it’s going to look like, they can
visualize what they’re going to end up with and then they start thinking about adding some more features,” Russell states. “There’s just so much we can do with carved foam block supported by solid tube coring, that’s it’s relatively easy to add to or change the original project design.” As Russell has discovered
over the past 10 years of building Beyond Vertical Concrete, there’s not much he can’t do with concrete to create unique environments for clients who want more than just a stamped concrete patio. He admits that he wants to be able to create anatomically correct figures that he wants to incorporate into some of
An ordinary pool has been transformed into a backyard oasis. Photo Credit: Beyond Vertical Concrete
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DECORATIVE CONCRETE Russell and his crew use a hot-knife tool to shape the foam cores. Photo Credit: Beyond Vertical Concrete
designs, and you can be sure he will continue to try and fail until he masters that skill. That passion will continue to be his calling card around the world as he works with other concrete artisans who continue to expand the versatility and beauty of concrete. “I’m part of a network of 50 (concrete) carvers around the world and when a special project, like the one I just finished, comes up, we can bring the expertise and crew needed to complete the work,” Russell notes. “I’ll be heading to Australia in January to work with Mark Hodges, owner of Decorative Concrete Dimensions, on a project. Mark helped me complete the pool project. I just really like how this part of the concrete industry is developing.”
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UNDERSTAND THE DIFFERENCE REASONS TO CHOOSE CAT D & D2 SERIES MULTI TERRAIN AND COMPACT TRACK LOADERS OVER THE COMPETITION ®
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The competition hard mounts their undercarriage to the chassis resulting in a rough ride and accelerated track wear. The STANDARD suspended undercarriage on Cat® Compact Track Loaders isolates the operator and machine chassis from shock and vibration generated by rough terrain while conforming to ground conditions for maximum traction and flotation. This means you get a smooth ride, superior load retention, and longer track life.
The STANDARD modular one-piece sealed and pressurized cab delivers a clean, quiet working environment. The competition’s less effective sealing design includes an overhead door and two piece cab that relies on foam seals to join the two sections. The Cat Compact Track Loader’s air vents are effectively positioned to direct air to your body and/or feet, so you can stay cool on a hot day and warm on a cool day. Why pay for the competitor’s Heat/AC option if you can’t aim the air where you need it? Maximum comfort is achieved with Cat’s available High Back, Heated Air Suspension Seat with Lumbar, and arm bar adjustments. The competitor’s optional Air Suspension Seat does not include Heat, Lumbar Support, or adjustable arm bars.
Time is money and ease of access is STANDARD on Cat machines. Grouped service points and easy, ground level access allow you to perform daily/routine maintenance without using tools. This helps keep your machine running at optimal efficiency, reducing down time and increasing productivity. The competition’s CTLs require multiple tools to gain access to routine maintenance items. Large components must be unbolted and moved to access fuel, oil, and air filters.
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DECORATIVE CONCRETE
By Marty O’Mara
TO SEAL AND PROTECT: Preserving Decorative Hardscapes
The best way to ensure a hardscape’s lasting appearance is to apply a good sealer.
D
ecorative driveways, pretty pool decks and patios and wowworthy walkways … sometimes hardscapes are so much more than a slab of grey concrete. Hardscapes can include stamped concrete, acid stained concrete, integrally colored concrete, exposed aggregate and cementitious overlays; all designed to bring color and texture to your outdoor spaces. When hardscapes are meant to be just as visually appealing as they are functional, it makes sense to take steps toward preserving those surfaces to keep them looking good for as long as they’re usable.
There are many benefits to using a sealer on vertical and horizontal hardscape surfaces. Not only can a sealer enhance the beauty of colored, stamped or exposedaggregate concrete, but it also provides many practical advantages. A sealer will protect against water and chloride intrusion to minimize freeze thaw damage and it will block the penetration of chemicals, food spills, dirt, oil and grease to prevent stains. This is especially beneficial to decorative driveways. Sealers can also inhibit dusting and protect against abrasion and general wear and tear from things like patio furniture and foot traffic.
ALL ABOUT ACRYLICS For price and effectiveness, an acrylic sealer makes a great choice for use on hardscapes. A good acrylic sealer is economical, easy to apply, and is UV-resistant to chalking and yellowing. Acrylic sealers create a thin protective film that is breathable
to allow moisture vapor to escape. You can find acrylic sealers in wateror solvent-based formulations, each of which offers different qualities and sheens that can help you achieve the look you’re going for. In general, here’s what you can expect from each (note that there are exceptions and every product varies):
SOLVENT-BASED ACRYLIC SEALERS • Enhances color and creates a high gloss “wet look” • Longer lasting than water-based; reapply every 3-5 years • Typically has higher VOCs • Strong solvent odor • Can make surfaces slippery (nonslip additives can reduce this) • Flattening agents can be added to control the gloss level • Can be difficult to apply depending upon solvent composition and weather conditions Water-based Acrylic Sealers • Less enhancement of concrete
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aggregate and paste color • Offers a softer matte or satin sheen (lower gloss) • Typically not as long-lasting as solvent-based; reapply every 1-3 years • Usually meets all VOC regulations and can be an environmentally friendly option • No solvent odor • Easier to apply • Allows for quick and easy clean up Both options contain polymers which, though one is dispersed and the other is in a solution, form a membrane on the concrete surface to increase the gloss and enhance the surface color. Both are tough and durable and offer stain protection on concrete against food spills, chemicals and automotive fluids. Both are relatively easy to apply and are generally supplied readyto-use. All in all, once applied and given time to cure, both solvent- and water-based sealers function in very similar ways. The key differences are the resulting appearance, odor, VOC content and longevity.
natural looking finishes • Available with flattening agent • Available with anti-skid additive • Good working time Additionally, although counter intuitive, there are advantages to using a lower solids sealer on decorative concrete surfaces. This is especially true for areas that receive a lot of moisture from rain or sprinklers.
Lower solids sealers generally allow for better moisture vapor transmission. Higher solids sealers can restrict moisture vapor transmission which can lead to coating delamination or blistering resulting in a whitish, cloudy appearance. A lower solids, premium acrylic sealer with good moisture vapor transmission properties is generally easier to apply and
WHAT TO LOOK FOR IN AN ACRYLIC SEALER With so many options in acrylic sealers, it can be hard to know which one to choose. Acrylic sealers range in price and effectiveness. They’re not all created equal and it’s really important to consider the job specifics when making a selection. Take into consideration the elements and traffic to which your concrete surface will be exposed. For a stamped concrete driveway, you’ll want to find something that protects against oil and grease but this may not be a concern for your integrally colored concrete pool deck. To make choosing the right one easier, here are a few things to look for in a highquality acrylic sealer: • Proven history of good resistance to ultraviolet degradation • Good moisture vapor transmission properties to minimize the likelihood of blistering • Available in high gloss or more
• • • •
Add Value to Residential Concrete Attractive Hardscapes of All Kinds Improve Your Margins & Reach New Clients Stamping Tools, Stains, Stencils, Color, and Overlays
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DECORATIVE CONCRETE
“Thin to Win” applying a low solids solvent-based acrylic sealer. Photo Credit: Nox-Crete
will last longer compared to a higher solids version applied heavily.
APPLYING AN ACRYLIC SEALER Once you’ve chosen the best acrylic sealer for the job, you’ll need to consider the best way to apply it. After curing is complete, acrylic sealers can usually be applied by a pump sprayer or a roller. But keep this mantra in mind: Thin to Win. Total thickness should only be about 1-3 dry film mils, and this will help to avoid blistering. Two thin coats of acrylic sealer are better than one thick coat, and a pump sprayer followed by back-rolling usually achieves a thin coat better than a roller and pan. Remember that while acrylic sealers are easy to apply, they also dry quickly. Most acrylic sealers will feel dry to the touch in an hour or less and can handle light traffic in as little as 12 hours. Air temperatures and humidity will have an effect on dry times. Finally, always follow the manufacturer’s direction for applying their product.
REMOVING ACRYLIC SEALERS When it’s time for a fresh coat of sealer on your decorative hardscape, you’ll get the best results from
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Removing acrylic sealer using a biodegradable stripper with blanket. Photo Credit: Nox-Crete
removing what’s left of the previous coat. So, what goes on must also come off. There are a few methods that will work, each with their own pros and cons. • Petroleum-based solvents, such as xylene or toluene, dissolve the acrylic for removal. Most have harsh odors, are flammable, dangerous to your skin, and shouldn’t be used around children, pets or vegetation. Also, using solvents such as these in this way may not comply with local or state environmental or health regulations and at the very least will result in the accumulation of hazardous waste materials that must be disposed through a licensed hazardous waste handler.
• Biodegradable stripper and pressure washer can be combined to effectively blast away old acrylic. Surrounded areas should be protected against the stripper. This method does have the benefit of producing no hazardous waste. It should be noted that pressure washing alone is typically not very effective. • Sandblasting or grinding are aggressive techniques that can get the job done and pose no environmental risks but may do so at the cost of compromising the original surface. It’s also very laborious and can make quite a mess. Consider, also, OSHA’s Respirable Crystalline Silica Dust Standards which set very strict rules regarding exposure to silica dust. • Biodegradable stripper with blanket methods are easy, safe, and very effective. A fibercontaining blanket saturated in
a biodegradable stripper makes for an eco-friendly, fast and mess-free option for removing old acrylic sealer. There are few surfaces that are subjected to harsher environmental extremes than hardscapes. From the sun’s UV rays to heavy rainfalls to stressful freeze thaw cycles, outdoor concrete surfaces are put through a lot. And that’s just the weather. There is also heavy foot traffic, vehicular traffic, food stains, dirt, deicing salts, grease, oil, and more that can damage and blemish decorative hardscape surfaces. Considering all this, the cost and time of applying a quality acrylic sealer is a small price to pay to protect hardscapes for which you’ve put so much effort into making beautiful. Ed. Note: Marty O’Mara is the Decorative Market Segment Manager with Nox-Crete. He can be reached at momara@nox-crete.com.
Distributed by:
Brokk Inc. | Monroe, WA | 1-360-794-1277 | info@brokkinc.com | www.brokk.com ForConstructionPros.com/10072268
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DUO Handset Formwork System Simple. Lightweight. Versatile. Simple. DUO panels are clamped together intuitively in seconds without the need of any tools. Lightweight. DUO is a true handset system, weighing only 4 lbs/ft2 with standard panel sizes at about 3 ft x 41/2 ft, it is specifically designed to be handled without the need for a crane. Versatile. DUO panels can be used as wall, column and slab formwork. Columns are now available in imperial sizes up to 24“ x 24“ inches.
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PRODUCT FOCUS
By Aaron Boerner
Remote Controlled Demolition Machines Key to Demolition Phase of NBA's Second Largest Renovation Project SSD Demolition and Environmental slam-dunks the Philips Arena project deadline with a fleet of demolition machines 44 Concrete Contractor | August/September 2018 | www.forconstructionpros.com/concrete
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J
ust as basketball players often need to score big before the buzzer to win, the contractors completing the NBA’s second-largest renovation ever need to work fast to make sure the athletes have a court on which to compete. The Atlanta Hawks announced a $192.5 million re-imagination of the Philips Arena in downtown Atlanta in June 2017. The threephase project involves rebuilding the interior of the building from the roofline to the baseline, as well as making major changes to the arena configuration. The result will be new amenities on every level of the arena, a tremendous amount of open and connected space, new video boards, improved sightlines and the first-ever bar on an NBA playing floor. The Atlanta Hawks hired a team of general contractors comprised of Turner Construction Company, AECOM Hunt, SG Contracting and Bryson Constructors to oversee the project. The first phase was chiefly demolition focused, requiring — among other things — removing a six-level wall of suites on the arena’s west side to make room for many of the improvements. Not only did the phase involve demolishing almost 3,000 tons of concrete, it also needed to be done in just 12 weeks to be ready for the new basketball season and upcoming concerts. Plus, unlike most projects where one contractor finishes and another begins, all contractors had to start working on the arena at the same time with no slack time built in. SSD knew using remotecontrolled demolition machines would improve productivity over handheld tools, as well as keep workers safe from flying concrete and fall risks. Brokk Atlanta-based demolition contractor and NDA SSD used an Atlas Copco SB 202 hydraulic breaker attachment, and the unique Brokk three-part arm design allowed them to take advantage of extended reach capabilities and precise demolition. Photo Credit: Brokk
member SSD Demolition and Environmental (SSD) bid on the project. The traditional method of wire-cutting chunks of concrete from the wall of suites and craning them out would take a long time and involve too much use of the general contractor’s crane, which was needed for many parts of the project. Company planners proposed using innovative remote-controlled demolition machines to deconstruct each level, starting from the top and working their way down. The method would improve productivity over handheld tools, as well as keep workers safe from flying concrete
Brokk, in 2017 during a difficult topdown demolition project. Research at the time determined that suspending one of the machines from a crane was the best way to complete a safe, controlled demolition. SSD rented one for the 2017 demolition and continued to regularly rent the equipment. Based on their experience over the years of renting, SSD management knew purchasing the machines would be a good investment. When the first phase of construction began in June 2017, SSD crews moved quickly, starting demolition of soft ceilings, offices,
and fall risks. The general contractor hired SSD based on its proposal. “Our plan to use these specialized machines was what won us the project,” says Gregory Gorman, SSD senior vice president. “The equipment is remarkably powerful for its size. Plus, the electric-powered machines eliminated the risk of exhaust fumes, which was a huge benefit for the interior demolition that was the bulk of our work.” The contractor purchased two Brokk 160 remote-controlled demolition machines, which were vital to their plan. The company learned about the manufacturer,
SSD knew using ribbon boards, remote-controlled retractable demolition seating, premachines would improve cast seating productivity over and vomitory handheld tools, walls. Crews as well as keep workers safe from also installed flying concrete and scaffolding, as fall risks. well as deflection Photo Credit: Brokk shields and chutes, for rubble containment and removal. Demolishing the concrete suites by deadline required a strict six-daya-week schedule with a 42-person crew rotating through two 10-hour shifts. Starting at the top level,
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PRODUCT FOCUS the contractor placed one B160 at the north end of the stadium and the other at the south end. Two operators manned each machine — one using the remote control and one as a spotter. From there, operators worked their way toward the middle of the suites, demolishing concrete, pillars and utilities, as well as seating, handrails, floor and wall coverings, drywall and other items. SSD used an Atlas Copco SB 202 hydraulic breaker attachment, and the unique Brokk three-part arm design allowed them to take advantage of extended reach capabilities and precise demolition.
SSD wrapped up its portion of the project after 74 days of work, three days ahead of schedule. In total, the contractor recycled 2,760 tons of concrete from nine arena levels. Photo Credit: Brokk
RISE AND GRIND.
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Operators switched to a steelcutting attachment to cut through rebar, which reinforced much of the concrete. SSD President Michael Gorman said the attachment was a dramatic improvement over needing to cut with handheld torches. “The Brokk salesman, John Haugabook, brought the attachment when he delivered the machine, anticipating our need to cut rebar,” Gorman says. “We’re glad he did. We tried the attachment, recognized the improvement to our process and bought it on the spot. Overall, the Brokk machines improve our productivity by as much as 50%.” At night, the second crew cleaned rubble from the level below the day’s demolition areas. Workers loaded debris into hoppers by hand and with mini excavators and skid steers. A deflection field composed of plywood and scaffolding on the
levels’ edges provided both fall protection and a way to contain rubble. Workers also used debris chutes and a service elevator to remove material. SSD wrapped up its portion of the project after 74 days of work, three days ahead of schedule. In total, the contractor recycled 2,760 tons of concrete from nine arena levels. Each level took about a week to complete. The crews removed 300 to 410 cubic yards of concrete from each level. When the two Brokk machines met in the middle, the general contractor’s 350-ton crane on the arena floor moved the B160s down to the next level to begin the process again. SSD used the Brokk machines for about four weeks to completely remove the suites’ walls. Beyond the suites, SSD completed additional architectural and structural demolition of major arena
components. This included removing concrete slabs and foundations, as well as modifying raker beams and stairs. SSD wrapped up its portion of the project in September. Overall, phase one construction wrapped up in late October — just in time for an Eagles concert and basketball season to begin. Work on phase two began in November 2017. Phases two and three involved additional architectural work and the bulk of the construction of the new amenities, additions and layout. The project was completed for the 2018-19 basketball season, coinciding with the Hawks’ 50th anniversary in Atlanta. Ed. Note: Aaron Boerner is a writer for the construction, demolition, aggregates and mining industries.
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CONCRETE
By Joe Nasvik
Ultra-High Performance
concrete A type of concrete you haven’t heard about, but should.
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W
hen normal readymix concrete is made, the largest aggregates in the mix can range from 1-1/2 inches down to 3/8ths of an inch in size with compressive strengths that can be as high as 10,000 psi. Good mixes are “well graded” meaning the voids between the largest aggregates are filled with smaller aggregates and so on down the line until there is the least amount of void space possible. Ultra-High Performance Concrete (UHPC) is like that except that filling the voids between aggregates is referred to as “particle packing.” Sri Sritharan, the Wilkinson Chair of Interdisciplinary Engineering at Iowa State University’s Department of Civil, Construction, and Environmental Engineering, Ames, Iowa, adds that particle sizes for UHPC are kept very small to create a more dense matrix, the largest size not exceeding 600 microns (about the size if a grain of silica sand). This helps increase the standard compressive strength of these mixes in excess of 22,000 psi. In the beginning it was called Reactive Powder Concrete (RPG) but that changed in the mid-nineties when it became known as UHPC. Research on this product originated in Denmark as far back as 1964 as a part of their effort to develop higher strength concrete mixes. Their research focused on very dense particle packed mixes with low water/ cement ratios and in the 1970’s the development of superplasticizers (High Range Water Reducers of HRWR) further helped to achieve low water/cement ratios. Dominique Corvez, Vice President and head of Ductal North America for Lafarge, whose headquarters in the U.S. are in Chicago, Ill., says they began to look at this technology in France too. Contractors experimented with it
first but LaFarge, one of the world’s largest cement producers, developed an UHPC product they called “Ductal” and it is still in use today. In the beginning every batch was made from scratch but today there are several commercial producers of packaged dry mixes. LaFarge Holcim is one of the largest producers of this.
ADVANTAGES OF UHPC Compressive strength is the most recognized way to characterize UHPC. As previously stated, compressive strengths are expected to be in the 22,000 to 30,000 psi range to be considered UHPC but research studies of cured UHPC under high pressure and heat have produced compressive strengths as high as 116,000 psi to date. But there are other unique advantages too. • High modulus of elasticity (MOE) which can be in the 7,500 ksi range • High tensile strength compared to normal concrete • UHPC has high bond strength to steel reinforcement and this can reduce the size of a concrete placement needed to bond concrete elements together • It has excellent resistance to freeze-thaw cycling without the need for air entraining admixtures
• Structural elements can be smaller and more lightweight compared to those made with normal concrete • Architects can design thinner concrete elements, improving the architectural appearance of their work • It is a very dense material with capillary pores eliminated making it impervious to water and salt penetration without sealing the surface • It has very low shrinkage and can be used as a non-shrink grout • It faithfully transfers even the finest relief from molded surfaces resulting in more ideal architectural concrete pieces Ingredients The goal for UHPC is to produce very dense impervious concrete by particle packing—arranging particle sizes in the mix so there is minimum void space between particles—in a very low w/c ratio environment. Similar to self-consolidating concrete (SCC), UHPC flowability is measured in “spread” rather than inches of slump. Spread UHPC is normally mixed on the construction site in small amounts with a high-shear pan mixer. But sometimes special ready-mix trucks are used. Shown here, ingredients are loaded into the drum for mixing. Photo Credit: Sri Sritharan
Workers are placing Ultra-high performance concrete (UHPC) on a bridge deck for the Iowa Department of Transportation. Precast panels and structurally tying the rebar together extending from the panels. Photo Credit: Sri Sritharan
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CONCRETE The Iowa DOT is exploring the possibility of using UHPC as a topping on their bridge decks. The nearly impermeable concrete is resistant to road salts and freeze-thaw issues and is very abrasion resistant. Photo Credit: Sri Sritharan
MIXING UHPC
diameters of 12-20 inches are common, making it easy to place and consolidate, resulting in very high strength and good resistance to environmental damage. There are many different mix designs for UHPC but they will use some or all of the ingredients below: • Cement. Portland cement with a little longer hydration process is preferred • Ground Limestone. Used as a fine aggregate • Sand. The largest size aggregate in the mix. • Quartz powder. Very finely ground silica which is used to provide vital particle sizes • Fly Ash. A supplementary cementitious material (SEM) that also helps with the particle packing process • Silica Fume. A SEM with particle sizes as little as 1 micron to help densify the mix. • Admixtures. Polycarboxylate superplasticizers (High Range Water Reducers) which are used to assist in the mixing and placing process and making very low
w/c ratios possible • Fibers. A range of fibers are being used in UHPC mixes. They include; steel, glass fiber, Poly Vinyl Acetate (PVA), polypropylene, and others. The amount of each depends on the material used but steel fibers are typically dosed 2% to 3% by volume of the mixture. This corresponds to 0.5 to 0.8 cubic feet of fiber and the fibers are very thin, usually 0.2 millimeters in diameter. • Water. The low amount of water, approximately a 0.2 water/ cement ratio, reduces shrinkage and increases the strength of the concrete
Due to the fineness of the materials and the very low w/c ratio mixing UHPC mixes requires special equipment. Sritharan says most UHPC is mixed on construction sites with high-shear pan mixers but he says he has been on sites where special ready-mix trucks were used. Mixing UHPC from scratch requires an involved blending process to properly distribute all the fine powder materials together. As a result, most UHPC construction applications today use pre-bagged products. For this and other reasons less than 1-1/2 cubic yards is typically mixed at one time.
HEAT CURING Sritharan says that subjecting UHPC to steam curing with temperatures in the 194ºF range develops high early strength. Steam curing for 48 hours enables UHPC to attain its full strength quickly and when high pressure is introduced with elevated steam temperatures it’s possible to greatly increase strength even more.
In the factory 5/8 inch thick UHPC panels are lifted by the yellow lifting device from the assembly line (top left). At the University of Cincinnati, Lindner College of Business (Cincinnati, OH) 23,000 ft2 of UHPC 5/8” custom aggregate curtain wall are being installed. Photo Credit: Taktl
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Conical Pour
4-Minute Driveway
Trolley System
82' Circular Pour
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CONCRETE
This shows what some of the possibilities are with UHPC cast dimensional corners, screens, and textures. Photo Credit: Taktl
CONSTRUCTION SITE APPLICATIONS UHPC is costly to make—much higher than standard concrete mixes and perhaps this is the reason its acceptance has been slow. But when all the benefits are considered it can be cost effective. In the U.S. infra-structure and bridge construction is currently the biggest UHPC user, mostly for connecting pre-cast bridge elements together. It is usual to provide 18 inch reinforcing bar overlaps for proper anchorage but UHPC installations require only 9 inches due to its superior bond strength. As a result concrete yardage for these junction spaces is much less and there is greater resistance to ambient conditions. Sritharan says the Iowa Department of Transportation is also researching the use of UHPC as an overlay material for bridge decks. A 1 to 1-1/2 inch thick overlay can supply ultimate protection for bridge decks, as they aren’t affected by salt, other deicing compounds or freeze-thaw cycles.
THIN ARCHITECTURAL UHPC COMPOSITE PANELS Kevin Gannon, RA, the Director of Program Development for Taktl LLC located in Turtle Creek, Pa., says one of their biggest problems is differentiating Architectural UHPC (A|UHPC) from civil engineered ready mix products and also Taktl products from Spray-in GFRC or extruded GFRC products. A|UHPC uses only non-metallic reinforcing fibers and often includes continuous mesh. Because of the thinness of UHPC panels, the mix design, and manufacturing methods favor flexural strength over compressive strength, while retaining all of the durability factors expected with UHPC. With the greatest resource for UHPC material reference standards being the Federal Highway Administration, architects are bound to have specification challenges. Taktl has made great strides with regard to establishing the reference standards and criteria for architectural UHPC facade applications. They focus their technical sales and project
management resources on educating designers and supporting contractors.. “Once they use the product they readily specify it on other projects,” he adds. Taktl originally focused on complex injected molded UHPC castings says Jason Flannery, the companies Design Director. It was an outgrowth of their metal outdoor fixture and furnishing business. They began to look at concrete because of how it could be shaped for facades. He says they began manufacturing UHPC facade panels in 2010, something no one else was doing in the US. They spent three years doing research and developing equipment. “We decided early on to develop the new company vertically—do every phase of the work in house from mold development and construction to innovating a continuous semi-automatic casting process,” he says. Today their only business is UHPC architectural concrete and they have a 200,000 square feet under roof with 150 employees. Last year they produced 1.5 million square feet of façade cladding, including hospitals, museums, university building and mixed use high-rise buildings – either field set in rainscreen cladding assemblies, or integrated into unitized façade systems. Dr. George Quercia, Taktl’s Director of Research says they produce UHPC curtain wall panels which are only 5/8 inches thick. Within this thickness are two layers of mesh as well as glass fiber reinforcement.
Typical panel sizes are 4 x 10 feet but they can cast up to 5 x 12 sizes and instead of forming each panel they cast oversize and trim them to size with concrete saws. These panels can replace 6-inch thick normal concrete curtain wall pre-cast panels. The thin panels reduce transportation costs significantly and economically extend the distance to construction projects. There is another advantage to architectural casting with UHPC— finely detailed mold surfaces are faithfully transferred to the casting due to the very small aggregates and paste structure of the mix. This makes it possible to create ever more detailed mold surfaces to achieve more stunning looks.
THE VALUE OF UHPC Though it is considered a new kind of concrete and doesn’t have much name recognition, UHPC has many advantages. Its great strength means that less material is needed to accomplish what regular concrete does. This can translate to engineering lighter structures starting with their footings. Water and ambient conditions that shorten the life of other types of concrete have little effect on UHPC because of its impermeable nature, providing a much longer pristine lifespan. Sticker shock might cause you not to give it a second thought but that would be a mistake. When everything is taken into account, strategic use of UHPC could turn out to be a bargain.
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SPECIFICATION GUIDE: VIBRATING EQUIPMENT
Vibrating Equipment A compilation of technical information when choosing your next concrete vibrator.
1 Allen Power Vibe-Pro
These concrete vibrators are the ultimate in hand-held gasoline powered vibrators. Both are lightweight, but powerful and provide excellent consolidation of concrete. • Rubber Vibrator Head Size: • Engine: Honda GX35 (35 cc) 2 in. (5.1 cm) • Horsepower class: 1.5 hp (1.1 kW) ForConstructionPros. • Shaft Lengths: 1 ft.Flexible shaft with rigid shaft extension com/20971167 Steel Vibrator Head Size: 2 in. (5.1 cm)
Model
Product Size (LxWxH)
Weight:
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length)
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
Power VibePro
N/A
N/A
9,000 vpm
1.5 hp
1’ flexible staff with rigid shaft extension
N/A
1”- 2”
Both
Gas
Model
Product Size (LxWxH)
Weight:
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length - inches)
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
AHFV22 High Frequency Vibrator
N/A
35 lbs.
12,000 vpm
1.57 hp
16.4’
N/A
2.2”
Round
Electric
Model
Product Size (LxWxH)
Weight:
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length - inches)
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
Power Vibe
N/A
N/A
9,000 vpm
1.5 hp
2’ to 10’.
N/A
1”- 2”
Both
Gas
2 Minnich Back Pack Concrete Vibrator
Minnich Manufacturing gas-powered back pack concrete vibrators maximize operator comfort, mobility and productivity. Features of the new 50 cc model and updated 35 cc unit include: • An ergonomically designed, fully adjustable harness that reduces strain and fatigue. • A throttle assembly with combined quick disconnect that allows the core/casing to be changed out in seconds. • A throttle assembly that is part of the core casing, enabling operators to use both hands to lower and lift the vibrator. • A throttle lock that lets operators move their hands up and down the core/casing while lifting and lowering. • Each model is equipped with a Honda mini 4-stroke engine for reliable performance. ForConstructionPros.com/12239627 Weight:
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length - inches)
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
19.5 lbs.
8,0009,000
1.3 hp
84”; 120”; 168”
7’ core & casing: 7 lbs.; 10’ core & casing: 9 lbs.; 14’ core & casing: 11 lbs.
3/4”; 1”; 1-3/8”; 1-3/4”; 2”; 2-3/8”
Round
Gas
Model
Product Size (LxWxH)
Weight:
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length inches)
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
Minnich Hand Held Concrete Vibrator
12” x 9” x 10”
12.75 lbs.
8,0009,000
1.3 hp
84”; 120”; 168”
3’ bent 2’ flexible shaft: 8.15 lbs.
3/4”; 1”; 1-3/8”; 1-3/4”; 2”; 2-3/8”
Round
Gas
Model
Product Size (LxWxH)
Minnich Back x 12” Pack Concrete 14” x 24” Vibrator
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3 Oztec BP-50a
The BP50a backpack concrete vibrator now has CE Mark approval certifying it has met EU consumer safety requirements. The vibrator features a totally enclosed rotary throttle that prevents wet concrete from entering and clogging the throttle mechanism. • Will run steel and rubber vibrator heads up to 2 1/2 in. • Vibrator heads develop 12,000 vpm and never drop below 10,000 vpm • Standard Quick Disconnect “QD” system, Honda gasoline engines and “speed-up” transmission • Kill switch conveniently located on the handle ForConstructionPros.com/10082973 Model
Product Size (LxWxH)
Weight:
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length)
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
BP-50a
15” x 18” x 23”
29 lbs.
12,000
2.5 hp
7’ - 21’
8 - 21 lbs.
1” - 2.5”
Round or Rubber Coated
Gas
Model
Product Size (LxWxH)
Weight:
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length)
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
Oztec 1.2 OZ/ 1.8OZ/ 2.4OZ/ 3.2OZ
N/A
12 lbs. / 16 lbs. / 17 lbs. / 22 lbs.
12,000
1.25HP / 1.75HP / 2.25HP / 3.25HP
2’ - 21’
2 lbs. - 21 lbs.
3/4” 2-3/4”
Round or Rubber Coated
Electric
Model
Product Size (LxWxH)
Weight:
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length)
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
Oztec RubberHead
1 7/8”dia x 14” / 2 1/2”dia x 15” / 2 3/4” dia x 15” / 2 3/4” dia x 6”
4.75 lbs. / 8 lbs. / 10 lbs. / 6 lbs.
12,000
N/A
2’ - 21’
2 lbs. - 21 lbs.
3/4” - 2-3/4”
Rubber Coated
Gas or Electric
4 VIBCO Stik-It Concrete Vibrator Mounts
VIBCO Stik-It Concrete Vibrator Mounts attach to concrete forms without the need to weld, drill or perform other invasive work. Providing exceptional performance and vibration transfer, Stik-It mounts on all types of concrete forms, even curved! Operators get the portability, versatility and ease of internal concrete vibrators with enhanced consolidation and finish quality of external concrete form vibrators. During concrete pours Stik-It quickly and effectively transports concrete throughout the form. ForConstructionPros.com/20971307
Model
Product Size (LxWxH)
Weight:
Vibrations (rpm)
#903
11” x 3-1/2” x 1-5/16”
1.56 lbs. (0.71 kg)
N/A
Model
Product Size (LxWxH)
Weight:
Vibrations (rpm)
#906
10” x 6” x 1-3/8”
3.24 lbs. (1.47 kg)
N/A
Model
Product Size (LxWxH)
Weight:
Vibrations (rpm)
#908
10” x 8-1/2” x 2-1/8”
4.38 lbs. (1.99 kg)
N/A
Power (hp)
N/A
Power (hp)
N/A
Power (hp)
N/A
Flexible Shafts (Length inches)
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
N/A
N/A
N/A
N/A
N/A
Flexible Shafts (Length inches)
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
N/A
N/A
N/A
N/A
N/A
Flexible Shafts (Length inches)
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
N/A
N/A
N/A
N/A
N/A
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SPECIFICATION GUIDE: VIBRATING EQUIPMENT
5 Atlas Copco SMART Electric Concrete Pokers
The 110V SMART electric pokers feature a radius of action that is 12 times the diameter of the poker heads, so they work faster to remove air voids. Available with 1-1/2 inch, 1-7/8 inch and 2-1/4 inch poker heads, their radius of action allow contractors to work in areas as large as 24 inches in diameter, which minimizes the number of dips. For easy maneuverability, the SMART pokers come with 32.8 feet of electrical cable and 16.4 feet of hose, with longer hose options available. ForConstructionPros.com/20971169
Model
Product Size (LxWxH)
Weight:
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length - inches)
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
SMART 40
590” x 4” x 4”
28.88 lbs.
12,300 vpm
.54 hp
16.4’
Tube Weight: 5 lbs.
Tube Diameter: 1-1/2”
Round
Electric
Model
Product Size (LxWxH)
Weight:
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length - inches)
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
SMART 48
590” x 4” x 4
32.4 lbs.
12,300 vpm
1.25 hp
16.4’
Tube Weight: 9.26 lbs.
Tube Diameter: 1-7/8”
Round
Electric
Model
Product Size (LxWxH)
Weight:
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length - inches)
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
SMART 56
590” x 4” x 3”
35.05 lbs.
12,300 vpm
1.57 hp
16.4’
Tube Weight: 11.5 lbs.
Tube Diameter: 2-1/4”
Round
Electric
6 Chicago Pneumatic Vektor 12K Electronic Pokers
Vektor 12K electronic pokers provide high centrifugal force, making them suitable for use across a wide variety of high-to-low slump concrete applications. All Vektor models feature a high-frequency motor-inhead poker and a built-in frequency converter (60 to 220 Hz), which allows them to be plugged directly into a standard 115 V wall socket. • The concrete pokers are available in two versions: a standard model equipped with a 16 ft. hose for vibrating concrete walls, bridges, and beams, and a devibrated E-version specifically designed for flooring applications. • At 12 times the unit’s diameter and a vibration frequency of 12,000 vpm, the Vektor series features an expansive radius of action and requires fewer insertions. ForConstructionPros.com/20971174
7
Model
Product Size (LxWxH)
Weight:
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length inches)
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
Vektor 12K40 Electronic Poker
300 x 100 x 80
N/A
12,000 vpm
N/A
N/A
N/A
N/A
N/A
Electric
Wacker Neuson’s New Flex Shaft Vibrator Motors The new “M” motors, M1500 and M2500, combined with a variety of heads and shafts, provide optimum concrete consolidation for every type of application. • The new M1500 and M2500 electric motors are lighter weight than previous models. • Wacker Neuson’s flex shaft system allows contractors to combine a variety of flex shafts. • The new M2500 motors is adaptable to all shaft and head combinations. ForConstructionPros.com/12239679
Model
Product Size (LxWxH)
Weight:
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length - inches)
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
HMS-flexible vibration system
Motors: 12.3” x 6.1” x 9.1”
11.9 lbs.
N/A
2.0 hp and 2.5 hp
19.7” to 354.3”
3.3 lbs. to 33.3 lbs.
1” to 2.75”
Round and Hybrid
Electric
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Without a
Honda Engine, your crew sees this:
Hard-working crews know that there’s a difference between equipment backed by a Honda engine and those that won’t stand up to the rigors of a demanding jobsite. From floats to compactors, compressors, pumps, and generators, real pros choose durable, fuel-efficient, and easy starting Honda GX Series engines on their equipment. Not to mention, the standard 3-Year Warranty* that backs up our legendary reliability.
Learn more at engines.honda.com *Warranty applies to all Honda GX Series engines, 100cc or larger purchased at retail or put into rental service since January 1, 2009. Warranty excludes Honda GXV140 and GXV160 models. See full warranty details at engines.honda.com. For optimum performance and safety, please read the owner’s manual before operating your Honda Power Equipment. ©2018 American Honda Motor Co., Inc.
ForConstructionPros.com/10071940
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SPECIFICATION GUIDE: VIBRATING EQUIPMENT
8 Wyco Sure Speed Electric Motor Vibrator
The energy efficient Sure Speed motor requires less power consumption by using only the energy necessary for job completion, produces less noise, and maintains a longer life span than competing motors. The Sure Speed produces uniform and repeatable vibration every time. The user only needs one motor to power any shaft length and head size. According to the company, Sure Speed meets the highest safety standards in the industry. The units meets UL60745-2-12 Electrical Certification and OSHA 29 CFR 1910.95 for noise decibels. Its lightweight, ergonomic design minimizes labor hours and fatigue. A soft-start brush design provides increased brush life. ForConstructionPros.com/20971181
9
Model
Product Size (LxWxH)
Wyco Sure Speed Electric Motor Vibrator
12” x 8.3” x 8.16”
Weight:
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length - inches)
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
16 lbs.
,500/12000 vpm
3 hp
24” – 240”
2 lbs. – 25 lbs
1” to 2.75”
Square
Electric
Rattle Stick Slump Buster Rattle Stick offers a Slump Buster extreme tool for use on larger floats or very stiff slumps. Every tool features a genius snap pole connection into any tool along with variable speed. You can support Concrete Cares with a vibrant pink tool purchase. ForConstructionPros.com/20971176
Model
Product Size (LxWxH)
Weight:
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length - inches)
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
Rattle Stick Slump Buster
30” x 2.25”
5 lbs.
8,000
N/A
N/A
N/A
N/A
N/A
Electric/Battery/Rechargeable
W I N C H E S
USTRY ION IND NSTRUCT O C E H T HES FOR TY WINC SPECIAL
BLOOM MANUFACTURING, INC. Custom Engineered Solutions Since 1910
(877) 958-5732
www.xtremepolishingsystems.com
ForConstructionPros.com/10075355
Independence, IA 50644, USA | bloommfg.com P: 319-827-1139 | 800-394-1139 | F: 319-827-1140 ForConstructionPros.com/10072208
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10 Northrock Pro 2+ Concrete Vibrator
The most popular of our electric vibrators the Pro 2+ will handle from 2’ to 30’ of flexible shaft and can run heads from 3/4” to 2 1/2” diameter. It is available with adapters that allow it to run shafts and heads from any other manufacturers vibrator. With an amperage draw of 15 amps it runs off a standard outlet. It’s heavy duty construction can provide thousands of hours of use. ForConstructionPros.com/21015896
Model
Product Size (LxWxH)
Weight:
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length - inches)
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
Pro 2+
8” x 8” x 15”
19 lbs.
10,000 - 12,000
2.5 hp
2’ to 30’
4 lbs. - 30 lbs.
2 1/2”
Round
Electric
Model
Product Size (LxWxH)
Weight:
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length - inches)
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
Pro 3+
8.5” x 8.5” x 16”
24 lbs.
12,000
3.3 hp
5’ to 60’
5 lbs. - 62 lbs.
2 1/2”
Round
Electric
11 Denver Concrete Vibrator GBPH25 Backpack Vibrator
A Honda approved application, Denver’s GBPH25 backpack vibrator is ideal for general construction projects such as footings and stem walls, decks, driveways, and stairways. ForConstructionPros.com/21015902 Model
Product Size (LxWxH)
Weight:
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length - inches)
GBPH25
N/A
29 lbs.
12,000
2.5 hp
5’ to 20’
Flexible Shafts (weight – lbs.)
Head Diameter (inches)
Head configuration: Round or Square (hybrid)
Power (electric or gas)
Round
Gas
1.25”, 1.5”, 5 lbs. - 62 lbs. 13/16”, 1.75”, 2”, 2.5”
LOW PROFILE
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Manufactured by: The Advance Metalworking Company, Inc.
ForConstructionPros.com/10896948
t isi !V ore 015 M 1 arn h # Le Boot
ForConstructionPros.com/10071817
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FOUNDATION Q&A
By James R. Baty II
RESOURCES – Never Stop Learning This summer, ACI has released the latest technical resource produced by this committee and now available for your business, ACI 332.1R-181 ‘Guide to Residential Castin-Place Concrete Construction’. This column discusses this latest technical document.
C
ommittee 332 has been a strong advocate and development force for improving the technical guidance and setting many appropriate standards for the residential industry. The first version of the Guide was published in 1984, was re-approved in 1999, updated in 2006 and re-approved in 2012. This 2018 version represents a significant update pairing with many improvements in the committee’s other major document for residential code requirements. Residential Code Requirements for Structural Concrete (ACI 332 2 ) and
Commentary was first released in 2004 with subsequent versions in 2008, 2010 and 2014 with the next version due to publish in 2019. Together, these documents work hand in hand to identify and shape the characteristics for design and construction of quality cast-in-place residential concrete considered for foundations, slabs, above-grade housing and more.
The American Concrete Institute has released the latest technical resource, ACI 332.1R-181 ‘Guide to Residential Cast-in-Place Concrete Construction’. Photo Credit: American Concrete Institute
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The evolution of these documents is important to identify along with the value of the latest resource itself. This is particularly true since the code requirements document was issued as the Guide document transitioned to a broader interpretation and practical implementation tool. In addition, both of these documents are part of the technical resources on which the ACI/CFA Residential Foundation Technician Certification was founded. Therefore, understanding some of the more significant areas of influence and update will help you prepare for certification as well as knowing what support exists for key technical issues you may face.
BACKFILLING Among the topics I’ve covered in this column, backfilling and excavating come up time and time again, whether it is related to safety, the designed performance of a wall or the achieved quality. Backfilling is
one operation that frequently places new residential foundations at risk for problems including cracking, water penetration and structural failure. Section 5.8 of the 332.1R-18 guide document increases the emphasis on recognizing the intended or assumed design for a residential foundation wall and how they must be treated for contractors and builders. The document states: “…the prescriptive designs [of ACI 332] for residential foundation walls assume a fully supported condition along the top and bottom. To be considered fully supported at the bottom, the floor slab should be a) in place and poured directly against the concrete wall, b) connected to the footing by keyway, or c) connected by dowels.” Mentioned here are important acceptable detailing methods for achieving the support conditions. Section 4.3.6 provides a discussion of the code allowance for dowels to
be wet set or pushed into the fresh concrete unless it is specifically prohibited by a local code or the project documents. Likewise, according to the code, these dowels can be preset in their location by driving them into the grade prior to concrete placement. Also found in section 4.3.6 is a discussion of the minimum spacing, the depth of extension into the footing and the minimum height of extension into the connected wall as required by the code. Section 5.8 continues the discussion for wall support stating the top condition “assumes that the floor framing and sub-floor sheathing are in place.” This is not new to our discussion (see Rationalizing the Standard Hook in a Residential Footing, December 2016) but one might ask the question, why does this matter? Foundation walls are designed like a beam and described as simply-supported members, hence the positive
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FOUNDATION Q&A connection at the top and bottom of the member. The pressure against the wall on only one side is the primary force it must resist as rarely is the weight of the house significant enough to consider in the design. As this section then states: “Walls that are backfilled without bracing or the floor framing in place are vulnerable to cracking, horizontal displacement, or bowing.” This is a big factor in the construction of foundations to deliver a quality wall, built to the intended design and specifications that has the capacity to perform outliving the above-grade structure of most residences. Therefore, backfilling is a key area of knowledge for certification.
POURLINES OR CRACKS Some information found in the Guide is intended to support the contractor in discussions with customers when facing concerns of performance. Among the most often visited topics is wall aesthetics and a common feature labeled a “pourline”. These are created when a delay occurs between concrete truck placements and the contractor is not able to sufficiently vibrate through the earlier placement. The owner or customer will often challenge this as a crack and a structural weakness in the wall. Section 5.5.10.3 states: “Pourlines are not cracks and do not result in propagation behavior nor do they present structural weakness in the wall, provided the surface of the concrete did not reach initial set before the next placement.” This section serves as advocacy for the contractor as well as a statement of practical application and caution for best practice…that is, be sure to not let the concrete reach initial set between load placements. The pourlines are most often very easily distinguished when the wall forms are removed as they appear nearly horizontal or at very slight angles, shaped to the natural leveling action of the concrete flow (see Visible Pour Lines – Are They A
Problem?, May 2014). In addition to the discussion of pourlines, 332.1R-18 also provides the reader with some recommendations on repairs for visible defects, indicating what are perhaps “normal” and what are features to be corrected. In section 5.5.10 crack widths less than 0.125 in. (3mm) are considered “normal” or acceptable as well as surface air pockets less than 0.75 in. (19mm). Beyond these conditions, the contractor should take care to patch or remedy these visible defects for the best customer relation and quality performance.
addition of blankets or protective sheets, auxiliary heat, tents, admixtures, increased cement content, use of high-early strength cement (Types III or HE), and higher concrete delivery temperatures.” The “why” for this issue is that it is imperative for the concrete to reach 500psi before freezing one time. If achieved, the durability of the concrete will not suffer the freezing and the contractor is then cautioned to maintain loading caution until they are certain the in-place concrete has reached sufficient strength to meet the requirements. For more information see Understanding
“Walls that are backfilled without bracing or the floor framing in place are vulnerable to cracking, horizontal displacement, or bowing.” FREEZING WEATHER A condition faced by most every contractor building foundations in regions north of 40˚ latitude and many more with experience above 35˚ latitude is freezing weather conditions. This affects water in the concrete mix and slows the rate of curing and is also another of the most significant concerns for customers. Experienced contractors know the behavior of concrete and the variation in curing performance between a residential foundation wall and a residential slab-onground. ACI 3063 is a very broad guidance document that presents a multitude of methods for protecting all concrete applications for proper curing and strength gain. However, it is important for the residential contractor to identify with the specific information effective for the two primary applications they face, walls and slabs. Therefore, to identify the most practical and effective methods to implement, 332.1R-18 states: “Protective measures include the
Concrete Maturity for Curing Cold Weather, December 2014 or Tips for Pouring Concrete Foundations in Cold Weather, December 2013. It is also important to know that 332.1R18 provides the guidance for form removal related to this same 500psi concrete strength. It is at this earlyage that can be considered selfsupporting. The guide provides: “Supporting forms, braces, and shoring should not be removed from wall forms until adequate strength is attained. Depending on climate conditions, curing procedures and the mixture proportions, the concrete should develop a minimum compressive strength of 500psi, which is typically sufficient for the wall to sustain its own weight in as little as a few hours after initial set. It is recommended, however, that the forms be left in place for a minimum of 12 hours.” This is not the time restriction for when the wall can support the real loads, that of the backfill and the vertical load of the residential
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structure, but it is when the wall will not be structurally impacted by form removal or at risk without the forms in place.
recognizes that it is also common for contractors to “rod” the concrete with a two-by-four piece of lumber or a steel reinforcing rod.
CONSOLIDATION
TOLERANCES
The topics of pourlines and surface air pockets are part of a larger construction issue for quality concrete referred to as consolidation. This is the process of densifying the concrete by putting energy into the flowable concrete mix to ensure it completely fills all spaces of the formed condition, sufficiently encompasses the reinforcement and embeds and moves entrapped air vertically through the mix to the top surface so that formed surfaces are as smooth, detailed or consistent as intended. The guide offers that the use of mechanical vibrators is the most common method for consolidation. However, it also
Conflict over the final tolerance of a structural element is not uncommon to residential concrete. Wall forms are erected according to the designed specification with great precision using laser stations. They are then filled with concrete and the forms removed 24 hours or so later revealing the hardened (or hardening) concrete wall. Movement in the forms, shrinkage from curing and other factors including the accuracy of the forming, shoring and bracing process can lead to conflicting dimensions and geometric relationships of walls and corners to the intended design. However, framing contractors may be working on a concrete foundation with
relatively exacting tolerances and end up with framed features that do not match the designed specifications. These conflicts are managed through guidance on acceptable tolerances. ACI 1174 is the general tolerance specification document from ACI referenced in codes and project drawings. As a guide, 332.1R18 interprets and provides further application of these tolerances specific to the common features of residential concrete projects and thoroughly describes how most out-of-tolerance conditions are not indications of structural deficiency or failure and should be handled amicably for moving forward as an entire team. It is therefore important to know these tolerances exist in Table 5.5.1.1 and that they represent indications for when contractors should consider ways to work with the customer and/or builder to
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FOUNDATION Q&A remedy conditions that may present definite challenges to the continued construction process. For example, table 5.5.1.1 provides for a foundation wall supporting non-masonry framing, there is an acceptable deviation of +/2 in. (50mm) for the edge of the wall from its designed location (see Out of Plumb May Not Mean Damaged and Unsafe, August 2015). Tolerances are also provided in section 4.5 for footings, which can be another source of anxiety in project conversations (see Acceptable Tolerances for Residential Footings, August 2017).
MATERIAL SPECIFICATIONS Guide documents also put in plain language many of the minimum requirements of codes such that the contractor can check off a series of details for the project. ACI 332.1R18 discusses the minimum concrete strength of 2,500 psi found in the 332
code document and then relates this to the maintenance of strength versus slump (section 4.3.7.1 and 4.3.7.2). The guide also delivers the primary specifications for steel reinforcement. Although it does further delineate why many of the walls found in the prescriptive code do not require structural steel reinforcement, it is present at all times for shrinkage and the guide helps rationalize its presence, the minimum type of steel (Grade 40), the common sizes (No. 4 & No. 5) and what to do when reinforcement bars overlap. It is a misconception to assume that wiretying steel bars together where they cross or overlap is sufficient. The guide describes the code application of “thirty bar diameters (30db) or 24 in. (610mm), whichever is greater”, in order to maintain the integrity of the intended presence. In the 2014 edition of the 332
code, a new section on durability and exposure was included. To residential concrete contractors, the reference to RF, RC and RS for exposure categories dealing with Freezing, Corrosion and Sulfate may seem foreign. Therefore, the guide discusses at length the determination of these exposure categories and the way mix designs should reflect the application of each particular category to the project.
TESTING The last featured item of the guide we will discuss is that of testing. During Concrete Foundations Convention 2018 in Utah this past July, Dr. Kim Basham spoke to attendees on the importance of properly taken, stored and controlled cylinders and more importantly, what happens when a bad break is returned. Section 3.7 of 332.1R-18
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delivers the summary information that all contractors should know when determining effective strengths through cylinder testing. It is this information that can make or break (figuratively) the tense discussion that comes from a statement of understrength concrete, though the reality is few residential concrete projects rely on testing cylinders. CFA is committed to creating greater awareness and better education on the technical aspects of the concrete industry. Rather than making assumptions on detailing or relying on the concrete producer alone to make decisions for sufficient concrete design, contractors need to recognize the resources available to them and spend enough time to understand them. This is a primary reason for the creation of the ACI/CFA Residential Foundation Technician Certification, to demonstrate and verify command
of these technical resources for use in projects. This certification is also the first step toward the ability of a company to achieve CFA Certified Foundation Company status.
References
1 Guide to Residential Concrete Construction (ACI 332.1R-18)published by the American Concrete Institute, 38800 Country Club Drive, Farmington Hills, MI 48331 | Phone: 248-848-3700 | www.concrete.org 2 Residential Code Requirements for Structural Concrete (ACI 332-14) and Commentary</u> published by the American Concrete Institute, 38800 Country Club Drive, Farmington Hills, MI 48331 | Phone: 248-848-3700 | www.concrete.org 3 Guide to Cold Weather Concreting (ACI 306R-16) and Commentary published by the American Concrete Institute, 38800 Country Club Drive, Farmington Hills, MI 48331 | Phone: 248-848-3700 | www.concrete.org 4 Specification for Tolerances for Concrete Construction and Materials (ACI 117-10) and Commentary published by the American Concrete Institute, 38800 Country Club Drive, Farmington Hills, MI 48331 | Phone: 248-848-3700 | www.concrete.org
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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e used te finish
Harley-Davidson Showroom Floor Designed to Focus on the Merchandise Simple, good looking and durable is what the HarleyDavidson dealership owners wanted for their 14,000 squarefoot Rocklin, Calif. showroom. by Greg Udelhofen Matt Bowen, owner of Prep Concrete, a decorative concrete floor finisher in El Dorado, Calif., is always up for the challenge, large or small, when it comes to delivering the best solution to a customer’s floor finishing needs. So, when the Harley Davidson dealership in Rocklin, Calif. presented a large challenge – 14,000 square feet large to be exact – on a tight budget, Bowen was excited. The project goal was to deliver similar colors to the Harley-Davidson color palette, to produce a medium sheen that would always look good, provide an extremely chemical resistant floor that would also resist
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scratching and tire pickup. The owners also wanted a surface that could be easily repaired if it was damaged. Bowen knew exactly how he wanted to deliver a high-quality finish for his client. He proposed using Endurable concrete stains and sealers to achieve the high-end results he knew would give the retail owner the look they wanted, but also stand up to the heavy Harley Davidson bikes that would be moved across the floor daily.
Grinding and patching took approximately a week and a half to complete, with most of that time spent on patching. But as Bowen knows, preparation is everything in the final finish of a project. So, after completing the final grinding, Bowen’s crew taped all adjoining walls to protect them from the stains and sealers he would use in the finishing process.
“Because of the large surface area, once we finished the initial staining we were able to begin the sealing process on the area we first stained,” Bowen says. “Mixing the gloss and matte sealers provided a finish with a subtle sheen, rather than real shiny or real dull.”
LET THE STAINING BEGIN
When entering the After the first Harley dealership, coat of sealer was bikes, accessories dry, Bowen went and clothing take center stage on the back to apply a new floor -- and lighter second that's exactly what coat of stain to Prep Concrete's Matt Bowen add more depth wanted to achieve. to the color finish. Then he went back to apply a third coat of stain consisting of 1:1 mixture of Pronghorn and Milk Chocolate with acetone to provide some accent coloring on approximately 40 to 50 percent of the floor surface. Bowen sprayed the
THE PREPARATION When a concrete floor finisher talks about the importance of preparation, Bowen is adamant about that fact and how important it is to final look and durability of any surface finish. After the carpet covering the 14,000 square-foot surface was removed, Bowen and his crew used a CPS propane-powered grinding machine equipped with 40-grit metal bonded diamond grinding wheels and an Ermator T8600 vacuum system to remove all the carpet glue. “One of the challenges of removing carpet glue is to make sure all of it is removed, and that means chipping it out of low spots and cracks,” Bowen states. “If you don’t go to that extent to remove all the old carpet glue, it may release after you apply fillers or the stains and sealers, and you don’t want that to happen.” He then went about repairing cracks and holes with Versaflex Quick Mender. Bowen then saw cut all joints and filled them with Metzger McGuire RS 88 Cardboard color, before using 70-grit metal bonded diamond grinding wheels for final surface preparation in order to begin the staining and sealing process. “It’s not only important to make sure all patch work has been leveled off and blended with the rest of the surface, but to also make sure you’re opening up the entire surface in order to allow stains and sealers to penetrate and bond to the concrete,” he notes.
Bowen used Endurable’s Pronghorn and Milk Chocolatecolored concrete stains to achieve the earthy tan color the Harley dealership owners wanted. Five gallons of the Pronghorn were mixed with one gallon of Milk Chocolate and six gallons of water. After applying the first coat of stain to the unsealed concrete, Bowen then locked in the color by applying a coat of Endurable sealer consisting of a one-to-one mixture of gloss and matte finish.
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accent coat using a fine conical tip that only disperses .05 gpm, allowing him to have absolute control over the amount of accent he wanted to create. â&#x20AC;&#x153;I was applying the accent in a fast manner, creating a marbled effect,â&#x20AC;? Bowen says. Following the accent application, Bowen then applied two more coats of sealer using a conical tip that dispersed .10 gpm of material. Bowen points out that after the Enduable sealer is properly applied and allowed to harden, you can always add more of the Endurable stains mixed with either water or acetone over the top of sealer. This capability provides greater variation of colors or the ability to hide or
Preparation is key to a quality finish and that's why Prep Concrete spent two weeks patching and grinding the concrete surface.
Depth and a mottled-color finish was achieved by applying several alternating coats of stain and sealer.
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It took two days to stain and seal the 14,000 square-foot showroom floor at the Rocklin, Calif. HarleyDavidson dealership.
repair defects in the concrete. It took Bowen’s crew two days to stain and seal the floor and a third day to allow the finish to completely dry and harden before the owners moved their shiny Harleys onto the surface. “The low luster mottled-color finish really showcases the bikes,” Bowen says. “I like the versatility and range of color finishes I can achieve with the Endurable line. I never use 100 percent of one color. I always use a variation of colors to create a unique finish. I’ve been working with it for seven years and I’m always impressed with what I can achieve.”
TAKING CARE OF BUSINESS For Prep Concrete, versatility in delivering unique results is important
to the varied client base it serves. From residential garage floors to breweries and Harley-Davidson dealerships, providing a unique and durable finish is what Bowen has relied on to build his business. Bowen handles a variety of floor finishing requests, from diamond polishing projects that can cost from $5 to $10 a square foot, to staining and sealing projects that can cost $2.50 to $3 a square foot up to $5 to $6 per square foot. “We’re a small crew of up to five or six people capable of handling a 200 square-foot project up to a 20,000 square-foot project,” Bowen says. “My experience has shown that water-based polyurethane finishes provide more durability,” Bowen adds. “And all customers want the finish to be chemical resistant, as well as resistant to tire pickup. The
Endurable line of stains and sealers has been my go-to solution. If you prepare the surface by sanding, etching or diamond grinding it to open the pores of the concrete to allow the stain and sealer to bond with the surface, you will be successful in achieving a quality finish.” For Bowen, that approach has served him well for the past 12 he’s been finishing concrete floors. With Customers are able to maintain the finish with dust mopping and occasional wet mopping, along with walk-off mats at entry points to the floor. “You don’t need to use harsh chemicals to clean the floor,” Bowen says. “You can wax the surface or re-seal them if you think they’ve lost the sheen you want. That’s it!”
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What is the Best System for Polished Concrete Maintenance? A comparison of traditional DIP (Diamond Impregnated Pads) and Composite Resin Abrasives (CRA). by Greg Cabot
“W
hat is the best way to maintain polished concrete?” This is a question many of us hear on a regular basis, So what is the right method? Is there one method proven to be superior? Today we are going to explore some field testing reviews, and compare traditional DIP (Diamond Impregnated Pads) to a newer floor maintenance system, which is being referred to as “Composite Resin Abrasives” or CRA. It is best to start this discussion with a definition of both products.
To determine whether the DIPs or Composite Resin Abrasives pad systems were the superior maintenance solution, they were compared head-to-head by Stone Sole Associates LLC. Two 126 square foot sections of “highly polished” concrete were sectioned off and “cleaned” using an Auto-Scrubber, utilizing each of the respective maintenance systems. Photo Credit: Ameripolish
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Starting with something more familiar to the industry is the Diamond Impregnated Pad. These types of pads, “…are produced by spraying, dipping, or otherwise applying a diamond-filled resin slurry onto the surface of a lofty, non-woven pad substrate” – Stone Sole Associates, LLC. Furthermore, after the phase of being sprayed or dipped they undergo a thermal curing phase. Product claims for DIPs are centralized around the idea that this method has a “chemical-free” cleaning capability. It is also a common claim that DIPs continuously enhance the aesthetic surface properties of the concrete. The newer technology of the two systems - dubbed “Composite Resin Abrasives” by its creators, is best described as a, “…hybrid design integrating a non-woven, diamond-free cleaning pad with separate, rigid composite diamond elements.” - Stone Sole Associates, LLC. What this means - put in more simple terms, is the abrasive portion of this pad is made separately from the non-woven pad, thus the “composite diamond elements” are independent of the pad, and not thermally cured to the pad, like that of DIPs. Due to the fact that the “Composite diamond elements” are independent of the pad, it allows the diamonds to act primarily on the exposed high points, and pass over the valleys or low points. What this does is over time, is it polishes down the high points, and transforms the surface into a flat “planar condition” best suited for a clearer, higher quality, light reflection.
PROCEDURE FOR TESTING
The color of the wastewater was brown in the DIP’s sample, due to the dye that was used on the polished concrete several months before the introduction of the maintenance system; suggesting the maintenance system abraded the concrete surface enough to remove dye.
To determine whether the DIPs or Composite Resin Abrasives pad systems were the superior maintenance solution, they were compared head-to-head by Stone Sole Associates LLC. During this testing, daily maintenance protocols simulated the long-term effects of both the pad systems. Two 126 square foot sections of “highly polished” concrete were sectioned off and “cleaned” using an Auto-Scrubber, utilizing each of the respective maintenance systems. Testing conditions were identical for each cleaning pad: approximately 40 lbs. of machine down-force at 80 ft. per minute forward speed.
Photo Credit: Ameripolish
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It took several days to complete more than 1,000 passes over the floor with each maintenance system. During regular intervals, surface quality measurements were made to check on the effects each system had on the floor with prescribed “daily” use. The quality measurements used were physical surface roughness (Rk), and aesthetic reflective image quality (DOI or Distinctness of Image).
RESULTS
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The Composite Resin Abrasive system produced “virtually no debris” in the wastewater sample collected after the 300th pass, and again later at 1,050 passes.
Sample Evaluation: The wastewater being used in the automatic scrubber was collected and evaluated throughout the process. During the Photo Credit: Ameripolish 300th pass the DIP’s reflected a large amount of debris within the water. This indicates that the DIP’s intended to maintain the floor were degrading not only the physical qualities of the floor, but also the aesthetic qualities of the polished concrete surface. The color of the wastewater was brown in the DIP’s sample, due to the dye that was used on the polished concrete several months before the introduction of the maintenance system; suggesting the maintenance system abraded the concrete surface enough to remove dye. The Composite Resin Abrasive system produced “virtually no debris” in the wastewater sample collected after the 300 th pass, and again later at 1,050 passes. The color of the water in the sample was not obscured with the brown color that the DIP’s sample contained, indicating that the long-term use of Composite Resin Abrasives is much safer for polished concrete than its competitors. Furthermore, the aesthetic qualities of the Composite Resin Abrasive section
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TABLE 1: As you can see, the DIPs actually increased the Rk values on each of the successive amount of passes, while the Composite Resin Abrasives decreased the Rk values on the same amount of passes. Photo Credit: Ameripolish ForConstructionPros.com/10896948
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were significantly better than the DIPs section. Rk Values: Now let’s dig into the numbers to reflect a better understanding of what each product is doing to the surface. With regards to Rk values, a lower number indicates a smoother surface, while a higher number indicates a rougher
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TABLE 2: The DIPs section of the test area started at a 72.9 DOI reading; and the Composite Resin Abrasive section started at a 67.07. Table 2 shows the progress of each systems DOI readings over 1,000 passes. Photo Credit: Ameripolish
surface. A higher the Rk value, has more scratches and abrasion on the surface.. At the start, the DIP’s section of the Polished Concrete surface was measured at a 34.98 Rk condition. The Composite Resin Abrasive’s section was measured at a 36.81 Rk condition; Indicating that even at the start of the testing, the Composite Resin Abrasive’s surface, was approximately 2 points higher (rougher) than the DIPs section. The following chart shows measurements throughout the test. As you can see, the DIPs actually increased the Rk values on each of the successive amount of passes, while the Composite Resin Abrasives decreased the Rk values on the same amount of passes. After 1,000 passes the Composite Resin Abrasive’s section was far lower/smoother (16.62Rk) than the DIP section (85.42Rk). This better explains why in the samples taken of the wastewater of the DIPs, there was color and aggregate inside; with each pass DIPs further scratch and abrade the surface of polished concrete. DOI Values: With regards to DOI values, the higher the number the better. DOI stands for “Distinctness of Image”, which measures reflected image quality/clarity. The scale runs
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0-100, the closer to 100 the more “mirror-like” the surface becomes. The DIPs section of the test area started at a 72.9 DOI reading; and the Composite Resin Abrasive section started at a 67.07. The following chart shows the progress of each systems DOI readings over 1,000 passes. As the study shows, even after only 100 passes, the aesthetic quality of the polished concrete surface maintained with DIPs has depreciated by 34.4%. In comparison to the Composite Resin Abrasives, increased its DOI readings by 27.3% over the course of 100 passes, indicating that it is actually improving the surfaces aesthetic quality over time. The test speaks for itself when it comes to aesthetic qualities within a polished concrete surface: Composite Resin Abrasives are a far superior method to that of DIPs.
value, it is actually more important to pay attention to what your price per square foot is going to be. Often times when the price tag value seems affordable, the price per square foot will reveal how expensive the product truly is. It is equally important to know what your maintenance system is doing to your floor. If your polished
concrete floor is being ruined by a “cheap” maintenance system, ultimately this will cost you more in the long run! Ed. Note: Greg Cabot is the Digital Marketing Manager at Ameripolish. He can be reached at GCabot@ Ameripolish.com.
SUMMARY This study reveals that since the emergence of new technologies such as Composite Resin Abrasives, there is a maintenance method that provides your polished concrete surfaces with far better results, than that of Diamond Impregnated Pads. It should be noted that DIPs are actually doing more harm than good when speaking in terms of physical and aesthetic qualities within your polished concrete surface, which essentially defeats the purpose of using it as a daily or weekly cleaning pad. With the integrity of someone’s job/work at stake, we all want to provide them with a maintenance solution that will keep them proud to return to the job site years later. Choosing Composite Resin Abrasives should be a concrete contractors first choice when recommending a long-term maintenance solution. As many of us know cost can be a driving factor when it comes to maintenance systems. While some systems have a good price tag
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Concrete and Silica – Three Factors You Need to Know If respirable dust is visible in a work area, adequate respiratory protection should be worn by workers in the contaminated area. Fortunately, there is growing awareness for the need for more adequate respiratory protection. by Alex Birrell
I
t is estimated that more than 2.3 million workers in the United States are potentially exposed to dust containing crystalline silica. Approximately 90 percent of those workers are employed in the construction industry. The silica hazard exists when various construction activities such as sawing, grinding, drilling crushing, etc. generates respirable dust that is released into the air. Why is this important? According to OSHA, in 2014 more workers died from silicosis than from being caught in or crushed by collapsing materials, such as in a trench
and structure collapses. These deaths were easily preventable with respiratory protection. Following are three important factors to consider when evaluating your respiratory protection processes: 1. THE HAZARD LEVELS: The OSHA silica standards call for different minimum APF ratings based on the types of jobs being performed and the level of ventilation where the job is taking place. Realistically to make sure a worker is protected for any situation, it’s recommended to issue respirators with a minimum APF of 50 be utilized. 2. COMPLIANCE AND TRAINING: Regulatory compliance is important, but employee acceptance and use is everything. After being properly trained and fit tested, if a worker still finds their respiratory protection uncomfortable, tight, hot or getting in the way of their work, they are at high risk of not using respiratory protection at all and/or incorrectly utilizing the respiratory equipment provided. When evaluating equipment, it is important to know your workers and the conditions they will use the equipment. For example, in dusty, hot, or humid environments a disposable N95 mask can become moist, clogged and collapse. By providing the worker an on-demand powered air flow, the respirator can
act like a portable fan pushing fresh air into the mask, thus cooling the worker, and is small enough to allow high mobility and portability. At the end of the day, you want workers to finish their shift with a clean face and no grit in their nose or mouth – reinforcing the message that the mask is protecting them. This will lead to much greater worker adoption and compliance. 3. TOTAL COST OF OWNERSHIP: Many businesses believe disposable masks are the most inexpensive and easy solution. Taking total cost of ownership, productivity and safety liability into consideration, disposable masks may be the opposite of cheap and easy. In fact, based on case studies at workplaces with modest respirator use, the annual total cost of ownership (per wearer) for a disposable N95 mask with an exhalation valve are high, given workers may go through as many
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as three-to-four masks in an eighthour shift. It may be higher in hot, humid or very dusty conditions. The main reason for high costs is that N95 masks are disposable and not reusable. As a result, companies may find a modern, powered respirator a far more cost-effective and safer alternative.
WHAT ARE TYPICAL COMPLIANCE ISSUES AND HOW THEY CAN BE COMBATED? Compliance issues generally arise from two common situations: 1. TRAINING AND EDUCATION: Respiratory equipment that is complicated, has many parts to
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assemble or is bulky and heavy, is less likely to be used – particularly when workers are mobile or working remotely. Deploying simple to use and light respirators significantly increases adoption and compliance. 2. COMFORT: If a worker complains about their respirator being uncomfortable, tight, hot or hard to breathe in, there is a very high risk they will look for ways to avoid wearing them or frequently leave the contaminated area to remove their masks. Both of these situations can be prevented by investing in modern, powered respiratory equipment that offers lightweight and compact design, simple assembly and operating system and cool fresh air.
HOW DO WE BEST ESTABLISH RESPIRATORY PROTECTION? With respect to silica exposure in construction and related fields, a respiratory protection program should be part of the overall Exposure Control Plan required by OSHA. This plan should be written and reviewed annually and take into account the various jobs and activities that can result in silica exposure. Your respiratory program should include the type of respiratory protection (and its Assigned Protection Factor) available and deployed for each job or area. The plan will outline how compliance will be managed and how workers will be trained. Companies should work with accredited safety or industrial hygiene professionals and/or their insurance companies to deliver a working program.
ABOUT THE AUTHOR
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Alex Birrell is the CEO of CleanSpace Technology, a company specializing in respiratory devices changing the way industries thinks about respiratory protection. Clean Space is headquartered in Sydney, Australia with regional presence in over 30 countries.
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INDEX ADVERTISER..........................................PAGE
ADVERTISER..........................................PAGE
Advance Metalworking Company..............................59 American Honda Motor Co........................................57 ASL Machines USA......................................................46 BackSaver.....................................................................70 Bloom Manufacturing Inc............................................58 BORIDE Engineered Abrasives..................................80 Brickform, A Div. of Solomon Colors, Inc..................39 Brokk Inc.......................................................................41 Caterpillar................................................................... 37* CDC Larue....................................................................63 Compact Excavator Sales...........................................53 Concrete Polishing Solutions.....................................61 CTS Rapid Set Cement Mfg Co.................................76 Curb Roller Mfg. LLC...................................................81 Denver Concrete Vibrator...........................................21 Driltec, Inc....................................................................29 Dust Collection Products............................................74 Endurable Concrete Products....................................35 EZ Polish System..........................................................75 GelMAXX......................................................................59 HTC Floor Systems......................................................73 Husqvarna Construction Products.........................2, 69 Hyundai Construction Equipment Americas Inc.......19 Jlin Corp.......................................................................11 Line Dragon, LLC.........................................................33 Lura Enterprises, Inc....................................................51 Max USA Corp.............................................................20
Metzger/ McGuire.......................................................74 Multiquip Incorporated...............................................15 Niagara Machine Inc...................................................36 Northrock Industries Inc................................................7 Nox Crete Products Group.........................................47 Oztec Industries Inc.....................................................84 Pecora Corporation.....................................................26 PERI USA................................................................ 42-43 Polishing Concrete University.....................................75 Reef Industries, Inc......................................................77 Rocky Brands Inc............................................................9 Simpson Strong-Tie Co., Inc.........................................5 Skudo USA Inc.............................................................28 Solomon Colors, Inc....................................................31 Somero Enterprises.....................................................25 Stego Industries...........................................................17 Superabrasive Inc........................................................71 Terrco Inc......................................................................65 Transhield.....................................................................27 Trinic..............................................................................36 US Saws........................................................................64 Water Cannon..............................................................81 World of Concrete.......................................................79 Xtreme Polishing Systems...........................................58 * Denotes Regional Ad
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THE LAST PLACEMENT
T
By Brad Humphrey
Why Foreman Should Work to “Polish Their Reputation”
he word polished, as I use it here, is intended to represent a more professional image to the Superintendents you will work with during your career. Quite honestly, many General Contractor Superintendents have a very low impression of many Subtrade Foremen, so it’s critical that we make a “polished” impression. Accomplish this successfully and the entire project becomes a more pleasant experience. Consider a few efforts to “polish your reputation” with the Superintendents you work with: • Be the first to introduce yourself and to shake the Superintendent’s hand…and demonstrate the same respect for the Superintendent each day. If, for example, the Superintendent is comfortable with you calling him by his first name, use it. However, if you don’t know, address the Superintendent as “Mr. Jones” until he instructs otherwise. If the Superintendent is female, use “Ms. Jones” until she says otherwise. • If the Superintendent brings some bad news or challenges to you, accept the input and thank them for their quick and honest information. • When you run into a challenge, first think through several options of solutions and then take the problem to the Superintendent. You’ll gain more respect if you will always think about potential solutions to challenges your crew is facing. • Never be slow about giving the Superintendent one of your company’s hats or T-shirts.
• Upon presenting the Superintendent with your schedule for the week, allow them to assess it quickly to see if it’s doable in their eyes. If not, quickly ask what you can do to adjust the schedule if needed. • If the Superintendent brings a request for something on your company’s part -- something that you know will not be received well -- redirect the Superintendent with, “Well, Ken, I know I will need to discuss that with my boss. I’ll let them know that we want to do it, but give me some time to contact my leadership and see about the possibility as we’ve discussed, or a better option if needed.” • If the Superintendent puts you on the spot for an answer… NOW…still divert, politely but firmly. Never let them pressure you to say something you may later regret. This is a little dicey to address, but you do not want to be “used” by the Superintendent against your own company. And believe me, some Superintendents are great at getting a “Yes” from the Foreman that conflicts with the “No” that they will receive from the Foreman’s boss. Don’t commit to a pressured request when you know that your leader will disagree. Simply hold your ground and inform the Superintendent that you will bring the request to your leader ASAP…if not sooner! • Never be afraid to have your workers pick up a little trash from other contractors. While you don’t want to purposely bring attention to the Superintendent
that you are doing this, Superintendents notice things like that more than you think. • No matter the Superintendent’s “temperature,” remain calm and cool headed. Even if he (or she) is shooting you with every creative and dirty phrase known to man, stay poised. Responding in the same manner will never allow you to win points with the Superintendent. Even the meanest Superintendent will circle back around and apologize to that Foreman who “took it” and didn’t respond in kind. Putting the “polish” on your efforts can certainly make you the “Preferred Foreman” in the eyes of the GC Superintendent. And in this way, your polishing efforts may make your company the preferred contractor, often leading to winning more work. If you are a Foreman, trying to find more ideas on how to get along with the Superintendent on your project, making an effort to “polish your reputation” will pay off on the current job – and future ones. Even if you are a Foreman leading a self-performing crew for your own company’s job, polishing your reputation will go a long way in making you more effective and successful. Determine today to make a more intentional effort to be Positive, Proactive and Polished. It will win you more fans and more work. Ed. Note: Brad Humphrey is President of Pinnacle Development Group and is known as “The Contractor’s Best Friend”. He can be reached at Humphrey.Brad@gmail. com.
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