How to Reduce the Cost of Concrete Production
26 August/September 2020
THE LEADING TRADE MAGAZINE IN THE CONCRETE INDUSTRY
Select Curb and Gutter Pavers to Meet
SMARTFLOOR POWER TROWEL Cuts Down Polishing Time at Florida Church
FUTURE NEEDS
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WHAT’S INSIDE
AUGUST/SEPTEMBER 2020 | Issue 4, Volume 20
COVER STORY
Cover Photo Credit: Timothy Schenck
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Monumental Project: In the Shadow of Lady Liberty How a concrete contractor solved the challenges of building a weather-resistant, durable, sustainable and iconic museum on Liberty Island.
DEPARTMENTS 4
Editor’s Letter
12 Products 42 Last Placement
FEATURES 16 Select Curb and Gutter Pavers to Meet Future Needs Because project requirements vary, it is important to understand the features and capabilities of the slipform paver and how that may impact future bid opportunities.
20 Dugan & Meyers Paves Way for New Rental Car Facility at Columbus Airport The new rental car facility was designed to be developed in phases to support the airport’s long-range expansion plan. It was projected to open in 2021 when COVID-19 impacted the area.
24 From Bid to Punchlist: Managing the Concrete Slab RFP Package Honest and accurate schedules, milestones and expectations must be communicated and clearly understood by all parties. www.ForConstructionPros.com/Concrete
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26 How to Reduce the Cost of Concrete Production Two of the toughest challenges for ready-mix producers are the lack of automation available and the cost and hassle of returned concrete.
39 Creating a World of Fantasy, Fun Through Pre-Blended Stucco In recent years, to bring realistic animal habitats to life and build seemingly unimaginable park rides, contractors have turned to advanced formula pre-blended stuccos.
32 Radiant Heat System Gets Boost from Molded Polystyrene Rigid Insulation Among the projects Daniel Morak and the USACE team are overseeing at Fort Carson, the U.S. Army Mountain Post in Colorado Springs, replacing an outdated airfield is the biggest.
36 SmartFloor Power Trowel Cuts Down Polishing Time at Florida Church A small church in Florida reaches out for help with its floor polishing.
WHAT’S ONLINE World of Concrete Gives 2021 Update Everyone’s favorite convention moves forward with in-person event. Search: 21139601
Watch Time Lapse Video of Allegiant Stadium 105,000 cubic yards of concrete were placed at the Las Vegas Raiders’ new home at Allegiant Stadium. Search: 21139126
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EDITOR’S LETTER Published by AC Business Media
Concrete Industry Events Going Virtual, Mostly
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event from September ortunately for 21-25. Concrete many, the concrete Foundations Association’s industry has (CFA) Concrete been largely shielded Foundations Convention from the business went virtual in late July slowdown associated with GIGI WOOD, EDITOR with avatars of attendees, COVID-19. Contractors GWOOD@ speakers and exhibitors. across the country have ACBUSINESSMEDIA.COM For now, World of reported that they're Concrete 2021 and 2021 PCI Conbusier than ever. That’s great news; vention at The Precast Show are we love hearing those stories. planning in-person events, with some One aspect of the concrete modifications. Hopefully, we'll be industry has changed dramatically: ready for in-person events by then. trade shows and conventions. For While it’s great that so many months, industry events have been in our industry remain busy and transitioning to virtual, online productive, we miss our friends and shows. That trend is continuing colleagues. There’s nothing like this fall, as many popular events getting up close and personal to the and meetings will take place online. equipment on display at trade shows. For example, instead of meeting in Seminars are much more engaging Raleigh, NC this October for the in person. Yet, even though life is American Concrete Institute (ACI) different right now, contractors are Concrete Convention and Excellence still learning and networking. Trade in Concrete Construction Awards, associations are reporting record the event will take place virtually on attendance in webinars and other October 26. online events. The National Ready Mixed Although these times are Concrete Association’s (NRMCA) challenging, we, like the industry, ConcreteWorks 2020, scheduled for are resilient. Before we know it, we’ll September 25-29 is now a virtual be back together, shaking hands and event. The National Mixer Driver sharing stories. Championship will no longer be an in-person competition, but a Mixer Driver Appreciation Week. Also in September is the American Society of Concrete Contractors Annual Conference, which will be a virtual
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Published and copyrighted 2020 by AC Business Media. 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 6 times a year: January, February/March, May/June, August/September, October/ November and December by AC Business Media, 201 N. Main Street, 5th Fl., 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 2020, Issue 3, Volume 20 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. Concrete Contractor is the Official Media Sponsor of the CFA Foundation Company Certification Program
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COVER STORY
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BY GIGI WOOD, EDITOR
MONUMENTAL PROJECT In the Shadow of Lady Liberty
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t was a big-name project with countless performance requirements. There’s the logistics, such as shipping building materials to an island. It needed to withstand hurricanes and flooding, endure for more than 100 years and have sustainability woven into the design. The building height was not allowed to be taller than sea level, for fear of obscuring the view of the Statue of Liberty. It also needed to be iconic, but not overshadow the prized Lady of Liberty. The Statue of Liberty Museum was constructed on Liberty Island last year, meeting all of those performance requirements. The $100 million, 50,000-sq.-ft. structure was spearheaded and paid for by the Statue of LibertyEllis Island Foundation and the group had substantial expectations for the project.
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AWARD WINNER The problem solving and work that was needed to make the museum a reality was all worth it in the end. In July, the museum received a 2020 PCI Design Award for Sustainable Design. “The judges felt this was the best project for the sustainability award because it was designed for 500-year floods and it was designed to have an actual flooded basement, so there are panels with holes on the bottom of the structure that allow for the extreme events and extreme storms that occur,” says Roksana Taghizadeh, chief engineer for EnCon Design, one of the PCI Award judges. “Precast helped reach the building’s goals with limited maintenance and repair through flooding resiliency, with strong, durable material that can withstand saltwater.” The museum also achieved LEED
(Leadership in Energy and Environmental Design) Gold status with its green roof, locally-sourced building materials, flood-resistant design, bird-friendly glass, thermal bridge reduction, radiant floor heating, high-efficiency lighting, lowflow plumbing and thick insulation. “The basic design of the project has a lot to do with the landscape and specifically bringing the natural landscape up and around the building,” says Dan Piselli, director of sustainability for FXCollaborative Architects, the project’s designer. “When you look at the aesthetic intention, the building is trying to defer to the Statue of Liberty and the historic aspects of Liberty Island. And part of the way it does that is by blending in with the landscape.” The glass used in the building is bird friendly, to help counteract how integrated the building is with the landscape.
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The Statue of Liberty Museum offers unfettered views of Lady Liberty. Photo Credit: National Park Service
“We designed the glass such that there's a pattern on it that birds can see so they’re not fooled by the glass,” he says. “It’s a surprisingly large issue; up to one billion birds here in North America die by hitting a glass building. The project was accentuating and blending in with the landscape and we realized we might be exacerbating that problem. We were able to come up with a pattern on the glass that people could see out of quite effortlessly.” PRECAST MADE IT POSSIBLE Specially designed precast concrete panels played a big part in the building’s success, not only for its ability to improve logistics, but also for its weather resistance and sustainability. The insulated sandwich panels also allowed for improved insulation. “We added an extra inch of insulation, more than required by code and the connectors, the sandwich construction and selected a fiberglass type of connector, which isolates exterior precast from the interior precast,” Piselli says. “Between the additional insulation and thermally isolating connectors we had very high performance and wall thermal pointing, which leverages the thermal mass of the interior side of concrete.” Precast was used for thermal bridging reduction, as well. “Of course, insulation is important, but also thermal bridging is very important,” he says. “Once you're taking care of both of those things and pushing the build version again, the interior thermal mass of materials like concrete helps regulate the temperature inside the building. Once your heating and cooling system gets the wall to the expected temperature, then it helps keep it there, so that when people come into the space and their bodies are indoors, your temporary air goes in and out. The mass helps compensate for those interior loads so that the heating and cooling system doesn't have to compensate.”
BUILDING FOR RESILIENCY Project leaders wanted another type of sustainability, too: durability and resiliency. Not only did they want it to last for years, the building needed to be able to withstand seawater surges, winds and hurricane-level storms. “As a primarily concrete building and structure, the building is really designed to withstand floods and storms and designed to last a long time,” Piselli says. They considered steel frames but realized that might not be the best for an island surrounded by salt water. DeSimone Consulting, the engineer of record for the project, was discussing options for building materials with members of the foundation. DeSimone President Wajdi Atallah had worked with Bob Pabst, vice president of sales at High Concrete Group on various projects in the past, so he gave Pabst a call. “They were concerned about sustainability, long-term durability of any building materials selected,” Pabst says.
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The Statue of Liberty Museum, recently received a design award from PCI. The project also earned LEED Gold status and features bird-friendly glass. Photo Credit: Timothy Schenck
“They wanted to build a building that could last 500 years or more.” Atallah called Pabst asking if precast concrete would be a viable material to use in the project. “When they told me about the materials, colors and design motif, I started telling them what the attributes of precast were and the versatility of it, what you can do,” he says. “I said, ‘We can come up with a hybrid structural frame where you take the benefit of the precast walls around the building enclosure to be load bearing. And we could take the shear and load of steel from an interior steel frame. They liked that idea because they didn’t want a lot of steel around the perimeter. With precast, you don’t need it.”
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COVER STORY CONTINUED Photo Credit Timothy Schenck
Precast concrete panels were used to construct the museum. Photo Credit: Timothy Schenck
For the interior, there could be more of a mix of materials. “For the interior, you have the steel columns and joists and make them connected to the walls,” Pabst says. “In the interior, they had this cast-in-place core for the elevator that provided shear for the building. They were concerned about shear for the structure around the perimeter and didn't want to pour more concrete or add more steel. I said we could use insulated precast wall panel product. We can design the walls to take that shear and they could take the load of the steel. They could provide shear for the building and the load bearing for themselves.” AESTHETIC DESIGN SOLUTION During the early stages of the project, FXCollaborative came up with an
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aesthetic plan for the building. They wanted the structure to appear as if it “rose up from the ground.” Not only were they in search of natural earth tones in the coloring, but they also wanted it to resemble the nearby landscape. Specifically, they wanted it to mimic the vertical striations of the Palisades cliffs along the Hudson River. High Construction designed precast panels to do just that. “Their vision for the building was for it to look like it rose out of the ground right up near New York Harbor, up the Hudson River is the Palisades Cliffs,” Pabst says. A PRECAST SOLUTION FOR FLOODING They also wanted the building to withstand flooding. “We had to then look at the weight load and relief holes in the wall panels as openings that allow the water to come in,” he says. “At the same time, we had to keep that panel fully insulated.
And we had to orientate them because at the floor level there had to be that water stop. On the design of the building, which is not that tall, we came up with a scheme for them to do panels along all the grade beams that were a certain height and as long as possible. In precast, a number of pieces can drive up the installation costs. You want to optimize the cost, the economies, to make a piece really big, but not too big where it's a big, permanent load.” While meeting all the criteria associated with insulation and sustainability, resiliency and waterproofing, as well as the aesthetics and striation façade, the team had to be careful about the width of the walls. “The interior panels, structural wise, were very hefty, 12 or 16 inches in and of itself,” he says. “Right then, the insulation was all 4 inches. The architect developed a profile design that wanted to show these vertical striations and they came up with a repeating pattern. It was a ribbed profile that had
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Zero Turn for Mobility
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info@gomaco.com ❘ www.gomaco.com Long, straight runs are nice. But many of you have curb and gutter projects with short runs, radii, and corners in parking lots or tight locations. GOMACO’s Xtreme curb and gutter machines have Zero-Turn capabilities for maneuverability. You’ll be able to place more curb than ever before and move your machine in ways you have never moved before. You’ll be able to pour a tight radius that you could only dream of before. GOMACO’s proprietary G+ controls makes your concrete paver smoother and easier to operate. Have fun paving curb and gutter with your new Zero-Turn GOMACO paver. Our worldwide distributor network and our corporate team always stand ready to serve and assist you. CONCRETE STREETS AND HIGHWAYS ❘ AIRPORT RUNWAYS ❘ CURB AND GUTTER ❘ SIDEWALKS RECREATIONAL TRAILS ❘ SAFETY BARRIER ❘ BRIDGE PARAPET ❘ BRIDGE DECKS ❘ IRRIGATION CANALS GOMACO CORPORATION IN IDA GROVE, IOWA, USA ❘ 712-364-3347
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COVER STORY CONTINUED The precast concrete panels on the exterior of the Statue of Liberty Museum were modeled after the Palisades Cliffs in New York, pictured here. Photo Credit: Wikimedia Commons
different dimensions out from base of the concrete, and I think the greatest one was about 4 inches. So, when you look at the cross section of the exterior width, you always need 3 inches continuous insulate concrete.” After a lot of collaboration, High Construction and the engineers were able to come up with a solution that accommodated the insulation needs, as well as the aesthetic pattern on the exterior wall. LOGISTICALLY SPEAKING One of the greatest challenges of the project was the site’s location. Instead of forcing each subcontractor to find their own transportation to the island, Phelps Construction, the general contractor for the project, hired a ferry and built a
receiving dock on the island. “It was a very smart move for them to tell all the vendors that Phelps is going to cover the costs for a ferry,” Pabst says. “They took cost of it for the entire job. All the trades didn't have to worry about figuring out that cost. High Construction could fit up to four of its trailers, batched concrete and
73 wall panels on one ferry trip. They took a crane over and assembled it on the island to place the walls. “We were able to drive the trucks right on the ferry and then drive them off, so it's eliminated that wait and down time,” he says. “And panels go up easy.” Pabst estimates months of construction time was saved by using precast. The entire project moved ahead more quickly and was able to avoid winter weather. “With precast, all your time is spent upfront in design and then in the factory making them, so to install the product, it goes up quick,” he says. “They didn't have to worry about weather, and they compressed their whole construction schedule.” The team had planned for reduced productivity because of the travel time. Overall, productivity was 30% better than predicted, Pabst says. Everyone involved has said they were proud to be part of such an iconic, and patriotic project. “It came out great, it came out beautiful,” he says. “If someone were to ask me ‘what project are you most proud of?’ It would be this one.”
For more information on the Statue of Liberty Museum project, visit ForConstructionPros. com/21139790.
The Statue of Liberty's original torch can be found at the new museum. Photo Credit: Epicgenius/Wikimedia
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The world’s #1 selling curb machine just got better. Power Curbers is excited to introduce the new 5700-D featuring the SlipSmart Control Solution providing operators a new level of precision. Our engineering is dedicated to provide you a reliable and productive machine that is easy to use. We stand behind our equipment with world-class support and unmatched commitment.
powercurbers.com Concrete Paving • Curb & Gutter • Barrier Wall Sidewalks • Bridge Parapet • Ditch Liners Agricultural & Custom Applications
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NEW PRODUCTS
A COMPILATION OF THE LATEST PRODUCTS TO THE CONCRETE INDUSTRY. Vacuworx PHD Portable Vacuum System
The PHD portable vacuum lifting system weighs just 25 lbs. yet generates enough power to lift up to 2,500 lbs. • Two dual-stage vacuum pumps build vacuum faster while drawing less power • 12V 30 amp/hour rechargeable LFP (Lithium Iron Phosphate) battery provides longer run time and overall longer battery life • Fast, efficient battery charger can be plugged in at night and be ready for a full day’s work in the morning • Designed to absorb vibration from the pump for quiet operation • Equipped with visible and audible alarms for safety www.ForConstructionPros.com/21113999
W.R. Meadows Hydralastic 836 SL
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W. R. Meadows’ Hydralastic 836 SL is its newest single-component, cold-applied, solvent-free, water-activated, waterproofing system. Hydralastic 836 SL cures to form a waterproofing membrane for both above-grade and below-grade applications. It will not crack in extreme cold or flow due to softening at high temperatures. Features include: • Fast curing at 75o F (23o C); no dust pick-up Save time and labor; easy self-leveling application Decreased blistering Cured with water addition in as little as two hours/Can be recoated same day for two-coat application
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Diablo Hammer Bits
Diablo’s complete range of SDS-Plus and SDS-Max Rebar Demon 4-cutter full-carbide head hammer bits withstand the stress of high powered hammer drills and the impact of rebar cutting. Produced with Tri-Metal Diffusion Bonding technology, the full-carbide head resists heat and prevents breakage. • Featuring a four-flute design for speed, this range provides faster dust removal, less wear • Diablo’s Rebar Demon range includes (74) hammer bits, covering a range of sizes: • SDS-Plus range: 5/32 to 1-1/8 in. • SDS-Max range: 3/8 to 2 in.
Honda Power Equipment CO-MINDER Carbon Monoxide Detector
Honda Power Equipment is equipping all models in its portable generator lineup with CO-MINDER, a new carbon monoxide (CO) detection system designed to help protect users from injury or death from accidental carbon monoxide poisoning. The system: • Continuously measures carbon monoxide levels in the air near the generator • Automatically shuts down the unit before detected CO reaches a dangerous level Four models: •
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EU1000i and EU3000iS Super Quiet Series inverter generators for work, home and recreational applications Economy Series EG4000 open-frame unit for home backup and workplace power EB10000 Industrial Series generator, the company’s flagship model
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Baumer HeavyDuty Rotary Encoder
The HOG 10/POG 10 incremental rotary encoder provides features that can increase the fitting accuracy and is available with several sealing concepts for optimum protection in oily, damp, or dusty enviornments. • Wear-free seals that endure impacts by coarse and fine-grained solids • Sealing free from friction • High power output up to 550 m • Fiber optic cables ensure noise-immune signal transmission over a distance of 1.5 km • Heavy-duty rotary encoders, speed switches and tacho generators can be combined in one single robust, space-saving unit to provide varied types of output signals measured at a single drive shaft all at once • Large encoders such as HOG 16/22/28 from Baumer are used for maximum speed limit monitoring of large drive shafts under the most difficult conditions www.ForConstructionPros.com/21138271
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LIGHT HAS NEVER BEEN TOUGHER
The Stinger electric flex shaft motor has been designed to hold it’s torque in concrete under load, runs cool, and saves on vibrator head wear and tear. Rugged, agile, and depenable. A combination only found in a Minnich flex shaft vibrator.
Explore Our Entire Line of Vibrators WWW.MINNICH-MFG.COM
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NEW PRODUCTS Milwaukee Masonry, Concrete, and Tile Drilling Accessories
Milwaukee Tool will soon launch its new MX4 SDS Drill Bits, SLEDGE SDS Chisels, Hammer Drill Bits, SHOCKWAVE Multi-Material Drill Bits, and Glass and Tile Bits. • MX4 4-Cutter Rotary Hammer Drill Bits Equipped with solid head carbide, these bits deliver up to five times longer life in concrete with rebar. The 4-Cutter design prevents lock-up in rebar to reduce downtime while variable flutes remove dust faster, reducing heat and delivering up to 20% more holes per charge. Complete with a wear mark indicator, the MX4 4-Cutter Drill Bits show users when the bit no longer meets ANSI requirements. The new Rotary Hammer Drill Bits will be available in diameters from 5/32-in. up to 1-1/4-in. for SDS-Plus and 3/8-in. up to 2-in. for SDS-Max • SLEDGE Chisels Designed to stay sharper longer, Milwaukee’s new SDS-Plus and SDS-Max SLEDGE Chisels have reinforced edges and are designed with high-grade forged steel. The SLEDGE Family lineup is complete with bull points, flat chisels, scaling chisels, tile chisels and a scraping chisel as well as mortar knives and a floor scraper. • Carbide Hammer Drill Bits These bits are engineered with a precision ground tip. The wide flute design removes dust faster, reducing heat and delivering more holes per charge. Equipped with a ¼-in. hex shank, the new SHOCKWAVE Carbide Hammer Drill Bits are the ideal solution for drilling in masonry with impacts and hammer drills/drivers and will be available in sizes up to ½-in. • SHOCKWAVE Carbide Multi-Material Drill Bits These bits are capable of drilling through brick, block, concrete, steel, aluminum, ceramic tile, backerboard, wood, PVC and drywall. With an aggressive multi-grind carbide tip, these bits deliver up to 10 times longer life in stacked materials and up to 85% faster drilling speeds in metal. These multi-material bits are the ideal all-in-one solution with a ¼-in. hex shank for use with impacts, drill/ drivers, and hammer drills and will be available in sizes up to ½-in. • Tile and Stone Bits The new Tile and Natural Stone Drill Bits deliver up to two times life in granite, stone, ceramic tile and glass. An aggressive 8-grind carbide head delivers up to 20% faster drilling and a reinforced tip protects the head, providing the durability needed for use in hammer drill mode. • Glass and Tile Bits Equipped with an exact start tip for clean holes and minimal bit walking, the new Milwaukee Glass and Tile Bits are engineered with sharpened carbide to drill faster than the standard alternative. A reinforced carbide head provides increased durability when high-speed drilling into tile and glass. These bits are designed to be used with drill-drivers only, are not recommended for use on porcelain tile, and will be available in sizes up to ½-in. Meets ANSI B212.15 to fit common anchors.
Valtec Group 80 Grit Rotary Brush for Power Trowels
The 80 Grit brush rotaries for use on power trowels for scrubbing and stripping. • Non-rusting block with 80 grit silicone carbide impregnated nylon bristles • For use on surfaces where 80 grit is ideal • Primary uses include removing curing compounds, acrylic sealers and bond breakers, cleaning casting floors after lifting tilt-up panels, casting beds in precast, and cast-inplace forms • Can be used on green concrete to assist in exposed aggregate finishes • For use on walk-behind and ride-on power trowels www.ForConstructionPros.com/21139844
J.W. Speaker Solar LED Flasher Lights for Safety
High-powered, low-profile solar LED flasher lights help crews identify dangerous obstructions in a wide range of settings. The new lights are fully sustainable and offer visibility for up to one mile (1.6km) in any location where safety is a top priority, but power is unavailable.
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Sakrete App for Concrete Estimating
Working with concrete can create a bit of anxiety, no matter how big or small the job—whether you're placing a slab, leveling out a space for a patio or setting posts. • The first and most important step for any concrete project is to work out the volume of concrete needed – which isn't always easy, even for pros who are used to working in cubic yards. To make it easy, Sakrete developed a new Sakrete App that eliminates the guesswork. • Dirk Tharpe, Sakrete's go-to concrete expert affectionately known as the Carolinas' Concrete Cowboy, says, "While there is nothing wrong with traditional estimation, it's definitely not something most of us can do in our heads. Plus, not all jobs are easy rectangles. Adding concrete footings to posts or laying an irregularly shaped or curved slab can require meticulous measuring, or make you dust off your old geometry book, and that can slow you down."
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LEDs charge fully in six hours Can run for up to 120 hours Light projects perpendicular to the lamp for easier identification from further distances Impact-modified acrylic housing withstands UV light degradation Nearly indestructible Each light assembly is IP67 and IP69K rated and can withstand powerful high-pressure washers. Affix the solar maker lights to any object in a wide range of environments
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PCI High Concrete ThinCast
ThinCast is billed as the thinnest precast concrete rainscreen panel available on the market. ThinCast provides architects with the natural beauty and character of concrete in lightweight panels. The panels use a high-performance concrete mix to further increase strength by using corrosion-resistant stainless steel prestressing wires. • Application: Exterior / interior open joint, back ventilated rainscreen • Thickness: 0.75 in. • Installed Weight: 10.0 psf • Finish: Integrally colored panel with a media blast finish on exterior face only • Standard Nominal Sizes: 72-in. x 48-in., 72-in.x 24-in., 72-in. x 18-in., 48-in. x 48-in., 48-in. x 24-in., 48-in. x 18-in. • Joint Width: 0.50-in. minimum. Coordinate joint width and locations to accommodate story drift, window openings, penetrations and other features.
Concrete Properties • 28 Day Compressive Strength: 7,500psi (51.7 MPa), minimum per ASTM C39. • Entrained Air Content: ACI 318; 7.5 ± 1.5 percent per ASTM C231 • Freeze-thaw Resistance: Relative dynamic modulus ≥ 90% per ASTM C666 Mechanical Performance • Flexural Strength: 650 psi minimum, per ASTM C78 • Modulus of Elasticity: 4,433,000 psi minimum, per ASTM C469 Prestressing Wire • Type 316 Stainless Steel Wire. • Conforms to Federal Specification RR-W-410 Type VI, class 2, 7x7 • ASTM A492 – Standard Specification Stainless Steel Rope Wire • ASTM A1023 – Standard Specification for Carbon Steel Wire Ropes for General Purposes • Minimum break strength of 920 lbs
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MAX USA Battery-Powered TwinTier RB401T-E Rebar Tying Tool
The MAX USA Corp. RB401T-E's primary benefit is its ergonomic construction. The tool’s automatic contact mechanism/switch automatically forms a tie when pushed down over a rebar intersection. There is no trigger to pull. Users can adjust the handles to two positions, to find the most comfortable position for their height. The long nose attachment allows the tool to glide into rebar intersections with minimal effort from the operator. • Weight: 10.2 lbs. • Dimensions: 12-3/4-in. (H) x 16-in. (W) x 43-3/8-in. (L) • Minimum ties per coil: 155 • Maximum ties per coil: 260 • Applicable rebar size: #3 x #3 – #6 x #6 • Ties per charge: 4,000 • Tie speed: Approx. 1/2 sec. • Battery charge time: 65 minutes full charge (50 minutes 80%) www.ForConstructionPros.com/21139316
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NEW
RB401T-E The extended frame of the RB401T-E allows you to stand-up and tie rebar for concrete slabs. The RB401T-E uses the same battery and tie wire as the RB441T and RB611T TwinTiers. WWW.MAXUSACORP.COM | 800.223.4293 | AUGUST/SEPTEMBER 2020
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FLATWORK/SLAB
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BY CURT BENNINK, CONTRIBUTING EDITOR
Select Curb and Gutter Pavers to Meet Future
NEEDS
Versatility to pour more than curb and gutter, plus stringless capability should rank high on the list
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here are many jobsite application considerations to examine when selecting a curb and gutter slipform paving machine. “For example, what is the customer currently using and what are his plans for the future? We want to sell them a machine that provides solutions for today and in the future,” says Darick Franzen, vice president of business development, Miller Formless. “We want the customer to be able to maintain and have the ability to grow their business with our products, so understanding applications and plans for the future are important.”
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Slipform pavers come in many sizes with varying degrees of versatility. Select machines can be used to not only produce a variety of cross-sections for curb and gutter, but also sidewalks, median barriers and other shapes. Because project requirements vary, it is important to understand the features and capabilities of the slipform paver and how that may impact future bid opportunities.
GOMACO’s line of new Xtreme curb and gutter machines have rotarysensored slew drives on each of their three tracks for extreme steering capabilities. Their new hydraulics package allows inpedendent, individual control of track speed for smooth machine travel through a radius.
VERSATILITY EXPANDS OPPORTUNITIES “Versatility is a critical consideration when choosing a machine,” says Stephen Bullock, president of Power Curbers. “Very few machines can pour production curb and gutter in housing developments and DOT projects and fit into a tight parking lot for radius work, as well as being equipped for rehab jobs on city
streets.” Make sure you understand any limitations in what you can slipform with the specific paver being researched. Kevin Klein, vice president of engineering and R&D, GOMACO, adds, “We understand you have a specific and immediate need, but buyers need to plan for the future, as well. Why buy a machine only for curb and gutter applications, and then a few years later buy
Photo Credit: GOMACO
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a different paver for a barrier application or maybe a sidewalk or some other profile? GOMACO’s curb and gutter machines are capable of slipforming a variety of different applications in different paving configurations.” Also research features on the specific pavers. For instance, does the paver include a trimmer attachment to fine trim the subgrade prior to placing the concrete? Even on pavers that have trimming attachments, only a few allow simultaneous operation. “GOMACO’s machines are all equipped with fine grade trimmers to simultaneously prepare the subgrade for the curb and gutter to achieve maximum concrete yield on your project,” says Klein. MAXIMIZE PRODUCTIVITY THROUGH LABOR SAVINGS Most pavers offer a working (paving) speed and a travel speed. Paving speed is controlled by jobsite conditions, including concrete slump and the crosssectional area of the concrete being placed. Even the radius of the pour can impact paving speed, which will decrease as the radii gets tight. “Most machines pour at roughly the same speed. But efficiency can still be gained by selecting a machine that requires less labor,” says Bullock. The setup of the jobsite has a large impact on paving efficiency. “We want to provide a machine that adapts or responds to how well a job is set up,” says Franzen. “Subgrade, trucks, material and labor force all play into the speed of the machine.” Quality should be the main focus. “Paving speed and production is dictated by delivery of concrete,” says Klein. “Contractors should be equally or even more concerned about the quality of the product the paver slipforms. GOMACO machines have several features for a quality end product, including fine grade trimmers and a trailing stainless used on the mold. We can also provide driveway cutout devices to save concrete and labor through the driveways of a project.” For a jobsite with multiple pours in different locations, travel speed can also be a consideration for moving from site to site.
SELECT THE RIGHT PAVER FOR TIGHT RADII Depending upon the nature of your projects, the ability to handle tight radius pours is also important. This type of work requires careful planning. “You need to understand how many tight radii are on the project and the layout to efficiently get trucks and manpower throughout the project. The Miller Formless M-1000 four-track machine is very popular in 24-in. radius and straightaway slipforming,” says Franzen. You then need to select the best paver for the application. “Several manufacturers advertise tight radius capability,” says Bullock. “Does the machine fit in tight spots? Are additional sensors and setup time involved in preparing the machine for tight radius turning?” Compare setup time when selecting a slipform paver that will do a lot of tight radius curb and gutter. “First and foremost, [you] need a machine built to handle tight radius paving,” adds Klein. “The GOMACO GT-3600 was the first three-track machine to slipform a 24-in. radius. Paving through a radius with the machine rather than hand setting can save the contractor a good bit of material cost and labor.” Make sure the paver can productively handle a mix of straight and curved curb and gutter. “GOMACO’s line of new Xtreme curb and gutter machines do an excellent job in the straightaways, but are built for tight radii paving, as well,” says Klein. “They have rotary-sensored slew drives on each of their three tracks for extreme steering capabilities.” The paver controls can simplify tight radius pours. “The G+ control system easily interfaces with stringline or 3D guidance,” says Klein. “The Xtreme machines are also available with G+ radius software, which allows the operator to simply input the radius to be slipformed and the G+ calibrates and manages all aspects of traveling around the radius.” QUICKLY GET IN AND OUT To be successful in curb and gutter work, you need to be able to quickly get to the jobsite, set up, perform the pour, load up
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and get to the next jobsite. “Most contractors who specialize in curb and gutter work need a paver that can quickly and easily be transported from one project to the next,” says Klein. “The nature of Transportation and the their work is to spend just cost to transport should a few days on a project always be a consideration and move the machine in selecting a curb again as soon as it is machine. The cost of completed. GOMACO’s owning and maintaining curb and gutter machines a truck and trailer or are designed for jobsite lowboy continue to rise. mobility and quick and Photo Credit: Miller Formless easy transportability. They feature a side-shifting and vertical-lifting trimmerhead and mold and tracks that can turn more than 90o for quick loading onto a trailer. The molds used are also designed with the quickattach feature to allow contractors to change profiles quickly from job to job.” The cost of transport is also an important factor. “Being able to transport a machine with a dump truck and trailer has an advantage over those that must have a dedicated lowboy,” says Bullock. “Transportation and the cost to transport should always be a consideration in selecting a curb machine,” says Franzen. “The cost of owning and maintaining a truck and trailer or lowboy continue to rise. Situations that require lots of moves or tight work areas are always a factor. Is a smaller truck and tag trailer more efficient than a traditional lowboy setup? Cost-effective ways of moving any machinery are always of importance to a company’s bottom line. The weight and nature of the Miller Formless M-1000 makes it a favorite for fast and easy transportation from jobsite to jobsite.” A STRINGLESS FUTURE While you may not be using stringless technology now, it is going to continue to become more popular and should be a factor in the selection of a curb and gutter paver. As the technology continues to expand, pavers that are not compatible may become harder to sell.
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FLATWORK/SLAB CONTINUED Some slipform paving machines can be used to not only produce a variety of cross-sections for curb and gutter, but also sidewalks, median barriers and other shapes. Photo Credit: Power Curbers
The consideration of stringless compatibility is critically important, according to Franzen. “Is the machine capable and compatible with the three providers of stringless technology?” The number of jobs currently using stringless technology is hard to pin down. “Many of our customers at times go stringless after the machine has been delivered or used over a period of time,” Franzen notes. “Additionally, many road building companies use two different providers when it comes to this type of technology. However, as the industry continues to grow and demand this sort of technology it will become a higher percentage application. We are being asked more regularly about stringless abilities.” Stringless technology can handle almost any type of curb and gutter pour. “In today’s market, I think most applications can be slipformed with 3D technology,” says Klein. “We have many customers who will only use 3D control on their projects, while others are in markets where they use 3D on some projects while still setting stringline on other projects.” The technology is becoming user friendly. “3D stringless paving technology is becoming easier to operate and has been adopted on many concrete paving jobsites,” says Klein. “All GOMACO’s pavers are plug-and-play with the major 3D technology manufacturers — Topcon, Leica Geosystems and Trimble. We have a dedicated team of 3D experts in house to support customers adopting 3D paving while continuously working on new developments in 3D technology.” Upgrading pavers not initially designed for stringless technology can be cost prohibitive. “New Miller Formless pavers come equipped with MFSmart Control Stringless,” says Franzen. “However, it is very costly to
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upfit an older machine to go stringless. Most manufacturers are able to upfit machine controls to go stringless, however, it has not yet proven to be cost effective to upgrade an older machine.” SIMPLIFIED CONTROLS WIDEN OPERATOR POOL “Any contractor will tell you that finding labor, especially quality operators, is their biggest challenge,” says Bullock. “That’s why we focus on building operator-friendly, simple machinery. With just a few days training we can take someone who’s never been on a machine and make them a proficient operator. Simple controls and good visibility factor into this tremendously.”
Quick set up time, ability to pour radii and with minimal tie-ins at catch basins are bigger factors in productivity than purely machine speed Photo Credit: Power Curbers
Visibility is also important from a safety perspective, for operations and for monitoring the pour. “The operator needs to have the ability to see his surrounding area for safety’s sake and to properly operate the machine in an efficient, productive manner,” says Franzen. Control system location in relationship to the visibility of the machine pouring a curb can simplify operation. This includes the control system layout and the ability to run the machine remotely. “We design our equipment to be easy to use and operator friendly from all
aspects starting with the operator’s platform, which is isolated, reducing vibration and providing a more comfortable operating experience,” says Klein. “Some of our curb and gutter machines feature moveable operator’s consoles so they can be positioned for the best view of the entire paving operation no matter what the application being slipformed.” GOMACO curb and gutter machines can be equipped with an optional remote control to allow the operator to move away from the normal operating position if desired. “Our software engineers are constantly working to improve the G+ system,” adds Klein. “Because updates are incorporated inside the G+ software and not developed in completely new platforms, operators aren’t constantly having to learn a new system.” TRY TO CALCULATE THE TOTAL COST OF OWNERSHIP Curb and gutter slipform pavers vary from rather simplistic to very sophisticated and no one machine will meet the needs of every contractor. “Total cost of ownership does vary significantly,” says Bullock. “Machines that appear to be bargains going in sometimes carry very high-priced parts. A simple, well-built machine saves contractors with less time-consuming troubleshooting and expensive downtime repairs. A known machine like the [Power Curbers] 5700 series also retains its value at trade-in time.” Make sure to look beyond the purchase price. “Certainly, the initial upfront cost of purchasing such a machine can create some heartache. However, the real value in owning and operating this type of equipment is how long it will last and provide productivity and profits for the company long term,” says Franzen. Support of the machine, parts availability, off-site diagnostic abilities and training resources all play a role in the total cost of ownership, Klein adds.
For more information on curb and gutter machines, visit ForConstructionPros. com/21105206.
AUGUST/SEPTEMBER 2020 www.ForConstructionPros.com/Concrete
8/6/20 9:19 AM
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8/6/20 9:19 AM
FOUNDATION & WALLS
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BY LAUREN MANECKE, PERFORMANCE MARKETING
DUGAN & MEYERS Paves Way for New Rental Car Facility at Columbus Airport
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To meet the demands of the project schedule, Dugan & Meyers is using the lightweight and durable Stinger electric flex shaft concrete vibrator from Minnich Manufacturing. Photo Credit: Minnich Manufacturing
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olumbus, OH, is the 14th largest city in the U.S. and continues to grow. Before COVID-19, the city was building the most dynamic economy in the Midwest and was becoming a top travel hub. Millions of travelers from around the world were flying in and out of the city’s John Glenn International Airport each year. The growth of Columbus has created the need for more space to improve the airport’s traveler experience. With nearly 160 daily departures, the John Glenn International Airport sees a lot of traffic — not only from aircraft, but also from cars. As the number of annual passengers climbed toward 9 million, the John Glenn International Airport established plans to meet the growing demand for nonstop flights from Ohio’s capital city with the addition of a new concrete rental car facility that would open up about 40 percent more garage parking for travelers. Built on nearly 10 acres in the center of the airport property, the new, $140 million, four-level rental car facility will be one of the largest construction projects in the airport’s history. The effort includes a group of partners on which Dugan & Meyers is serving as the concrete contractor and the largest contractor on the job. Since opening in 1935, Dugan & Meyers has delivered a diverse portfolio of high-quality projects. The company enhances its construction reputation by focusing on exceeding the expectations of their clients. Building the concrete structure at the new John Glenn International Airport rental car facility has allowed Dugan & Meyers to exhibit their specialized strengths.
“This is the biggest job that I have ever stepped foot on,” says Josh Weddel, concrete assistant supervisor for Dugan & Meyers, a concrete construction contractor based in Columbus, Ohio. “Allowing travelers to drop off and pick up rental cars from a new, centralized location will provide a lot of benefits to the airport and travelers.” LEADING WITH LIGHTWEIGHT The new rental car facility was designed to be developed in phases to support the airport’s long-range expansion plan. It was projected to open in 2021 when COVID-19 impacted the area.
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Dugan & Meyers faced challenges when COVID-19 regulations became mandatory. Although the contractors have been able to work through the crisis, extra planning and necessary adjustments have been crucial to the jobsite efforts and keeping employees safe. “We’ve been fortunate to be deemed essential to work through COVID-19, but we have to social distance as much John Glenn International Airport established plans to meet the growing demand for nonstop flights from Ohio’s capital city with the addition of a new concrete rental car facility. Photo Credit: Minnich Manufacturing
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FOUNDATION & WALLS CONTINUED Photo Credit: Minnich Manufacturing
as possible and wear masks, which can be difficult on a jobsite,” Weddel says. “We have documented if a task has taken longer, but as of right now, we are still on track.” To meet the demands of the project schedule, Dugan & Meyers is using the lightweight and durable Stinger electric flex shaft concrete vibrator from Minnich Manufacturing. The Stinger is a 14.5-lb. doubleinsulated universal motor that can drive the full line of Minnich vibrator shafts and heads from 3/4 in. to 2 1/2 in. Available in a 15-amp (115-volt) version, it offers a more compatible speed range of 10,000 to 13,000 vibrations per minute (vpm) to meet today’s concrete placement challenges. The unit is equipped with a durable protective frame, which extends vibrator life with urethane end caps that absorb shock while supporting easy-to-grip handles. The Minnich Stinger provides quiet operation meeting Occupational Safety and Health Administration (OSHA) A 29 CFR 1910.95 standards. Using a 16-ft. core casing on the Stinger for curbs, short walls, columns, and footings, Dugan & Meyers was able to work efficiently and change heads quickly. The Stinger’s versatility was utilized while pouring many thin foundation walls, as well as deep and thick pours on support columns of the garage. “We’ve used high cycle vibrators in that past that have extra weight where our guys are dragging around a 60-70-pound vibrator,” Weddel says. “We knew we needed something lighter and durable for this project, and the Minnich Stinger had both of those things. With the Stinger being durable, you’re not fighting breakdowns like we have with other vibrators.” DISCOVERING BENEFITS The rental car facility is the first project Dugan & Meyers has used a Minnich product on. After receiving a recommendation from Dugan & Meyers Senior Project Manager Scott Marshall
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Photo Credit: Minnich Manufacturing
to use the Stinger, Weddel got in touch with Minnich. The connection between Dugan & Meyers and Minnich has led to a positive work experience. “It’s not most times that the owner — or even a guy that has the same last name of the product — will call just to ask how we are doing,” Weddel says. “They’ve been great to work with. They always keep in touch and get right back to me, which is another reason that I will continue to use their products.”
What started as the biggest job for some Dugan & Meyers team members will end in big benefits for travelers across the U.S. picking up and dropping off rental cars in Columbus.
For more information on this project, visit ForConstructionPros. com/21139913.
www.ForConstructionPros.com/Concrete
8/6/20 9:23 AM
Titen Turbo You’ve got to drive it to believe it. ™
Reliable installation. Less torque. Superior holding power. Meet the Titen Turbo, Turbo™, the next-generation concrete and masonry screw anchor from Simpson Strong-Tie. Its revolutionary Torque Reduction Channel traps dust where it can’t obstruct the thread action, drastically reducing binding, stripping or snapping. For a fast, easy and high-strength fastening solution, try our new Titen Turbo screw anchor. Visit go.strongtie.com/titenturbo or call us at (800) 999-5099 to learn more. ©2020
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Simpson Strong-Tie Company Inc. TNT20
8/6/20 9:23 AM
FOUNDATION & WALLS
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BY CHAD S. WHITE, BRYAN M. BIRDWELL
FROM BID TO PUNCHLIST: Managing the Concrete Slab RFP Package
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successful project starts during the bidding process. Defining the Request for Proposal (RFP) with a clear vision of the scope of work, job site conditions and work restrictions will go far in minimizing confusion and potential conflict. Honest and accurate schedules, milestones and expectations must be communicated and clearly understood by all parties.
DEVELOPING THE REQUEST FOR BID PROPOSAL The scope of work should be clearly defined and easily understood. Ensure during the bidding process that adequate time is allowed for the bidders’ questions and discussion. Do not assume anything; remember you have been looking at plans and documents much longer than the bidders and have an intimate understanding of how you want the project to proceed. Responsibilities should be detailed regarding subbase remediation, weather protection, housekeeping, safety and slab protection. “Apples to apples” is critical when evaluating competing bid proposals.
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You must dictate the scope of work you want priced and completed. Oftentimes contractors want to pick and choose what they want to bid and will qualify their bid based on factors that fall outside your intended scope of work. Accepting exclusions and conditional proposals only muddies the water and can lead to misunderstandings, delays and additional cost. Construction schedules, milestones, critical path and job site work restrictions should be clearly stated in the RFP. Claims for delay, extended general conditions and extra work can be frustrating, difficult to unravel and can lead to animosity and fractured relationships. Delays to schedule caused by weather or other uncontrolled acts should be covered and what the schedule recovery process will be should be clear. Recourse for contractor related delays and recovery options should be clearly understood. AWARDING THE JOB Fast tracking and hitting the job running is great, but do not fast track the award process. Take the time to
adequately evaluate the competing bids and after you have narrowed the bidder list down, do your due diligence and interview process. Obviously, you must determine the contractor’s financial viability and work history, but you also need to understand the contractor’s capabilities and plan of attack. One last point on the award process. Allow enough time between bid award and start of work. Every contractor loves getting the call saying you got the job, but nobody wants to hear, “Oh, by the way, we need you onsite next week.” The submittal process can be time consuming and developing concrete mix designs can take 30 days or longer in some cases. Many projects today require personnel background checks, medical testing and safety orientations that must be completed prior to personnel being allowed on-site. PRECONSTRUCTION PLANNING Depending on how involved or large a project is, having a preconstruction meeting with all trades is recommended. This is a great opportunity to introduce all the players, discuss administrative processes, job site rules and restrictions and schedule. Again, make sure the contractor’s field team is involved, at least down to the superintendent level. Long lead time items required should be discussed. The concrete contractor is going to want to know site access points, material and equipment laydown areas and general phasing of the project. Slab placement lay-outs need to be reviewed and approved by all parties. Method of placement, production rates and access required should be discussed and finalized. Ideally slab work will flow
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logically with minimal jumping around. Continuity of work is important. Review slab joint layout as it pertains to end use of the facility. Try to keep contraction (control) and construction joints to a minimum in high traffic areas. Slab mock-ups and test placements are terms that are often used interchangeably, but they serve two different purposes. Slab mock-ups are typically small placements of less than 10 cubic yards to evaluate concrete mix design and slab finish. These are typically not part of the building footprint, and several mock-ups may be required to confirm mix properties and final finish. It is important that the final approved mock-up remain in place during the slab placing operations as a reference point for slab finish comparisons. Test placements are typically large enough to review production means and methods, concrete delivery rates, Ff/FL results and slab setting characteristics. Test placements are typically part of the building footprint located in the least critical area of the building. Full size production placements should not start until all parties are comfortable with test placement results. Team building is important and should start during the preconstruction phase. Encourage your concrete contractor to attend weekly jobsite progress meetings as soon as the bid is awarded. Get them on board and contributing input to the building plan. Pre-placement meetings are crucial to getting off on the right foot. They should be scheduled prior to test placement and should not be more than two weeks ahead of scheduled start of production placements. You will want to invite design team, testing agencies, concrete contractor and his sub trades, ready-mix producer and all general trades that have work or coordination issues with the concrete placements. Agendas can come from either the concrete contractor, general contractor, or a representative from the facility end user. No matter who conducts the meeting it is important that at a minimum the following items are discussed and reviewed: • Schedule and slab placement layout • Start times, work restrictions and
production rates • Concrete mix design, floor finishes and Ff/Fl requirements • Contractors means and methods and any special needs • Environmental concerns, weather protection and slab protection • Slab plan details and specifications • Testing procedures and requirements • Contraction (control) joint installation and curing • Specialty floor treatments or coverings CONSTRUCTION PHASE, PREPPING AND PLACING SLABS Who or what is driving the job? Most projects are schedule driven and have a critical path. Through the years most slab projects we have been involved with seem to hinge on one or several of the following activities: building pad completion, steel deliveries and erection, critical equipment delivery dates, roof completion and weather. Typical all-trade daily reports may be adequate to capture pertinent detail related to slab placements on small or repetitive placements, but we recommend that a separate slab placement report be used for any significant placements. Important data that should be recorded for a slab placement: • Placement size and configuration • 24-hour weather data • Actual start of placement, placement complete and slab finished • Concrete rate of placement • Placing slumps • Record of any delays longer than 30 minutes • Subbase condition or other under slab Pictures and video are great, and we suggest at least 10 pictures taken throughout the place, finish, saw and cure process daily. Standards for quality will have been established with mockups and test placement and continuing adherence to expectations needs to be monitored throughout the slab placement sequence. Most of the conflicts and disputes during slab placements can be traced to jobsite conditions (subbase remediation, weather protection, etc.), schedule constraints/demands, coordination with other trades and “not in my bid”
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differences. If you have ground rules in place for managing these situations your project will run smoother. Field directives and communications should be formalized and recorded. DEVELOPING A PUNCH LIST AND MANAGING THE WARRANTY PERIOD The purpose of doing a punch list is to identify work in place that does not conform to plans and specifications or is not up to standards established for the project. We have found that the easiest way to manage this activity is to be proactive, identify and correct these issues as they come up during the construction cycle. Typical slab punch list items: • Concrete splatters, excess mortar on walls, floors, columns, and imbedded items • Out-of-joint cracking. Crack widths < 30 mil wait & watch, >30 mil repair. We do not advocate removing slabs just because of a crack. Dependent on slab design and location of crack, floor durability and longevity will not be compromised. If the owner or end user refuses to allow any out of joint cracking in the slab, this needs to be communicated clearly during the bid stage. • Slab curling at joints, columns, and walls. A certain amount of shrinkage and curling can be expected in most slab designs, and unless floor usability is compromised this item should not be addressed. In areas where curling is problematic grinding is usually the best correction. • Spalls, aggregate pop-outs and cosmetic blemishes Warranty terms and length are typically spelled out in the contract documents. Communication with facility managers should be maintained while the warranty is in effect, and periodic inspections should be conducted. A final warranty walk through should be done prior to the end of warranty period, and a representative from the concrete contractor should be present.
For more information on managing projects, visit ForConstructionPros. com/21139318 .
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CONCRETE TECHNOLOGY
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BY GCP APPLIED TECHNOLOGIES
How to Reduce the Cost of Concrete Production From creating and transporting concrete to eventually receiving leftover concrete, there are opportunities to help ready-mix producers improve efficiency and reduce material waste, thus reducing costs. Photo Credit: GCP
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oncrete is quite literally the foundation of most of our infrastructure. However, the process of concrete production has remained relatively unchanged for decades. From creating and transporting concrete to eventually receiving leftover concrete, there are opportunities to help ready-mix producers improve efficiency and reduce material waste, thus reducing costs. Two of the toughest challenges for ready-mix producers are the lack of automation available and the cost and hassle of returned concrete. THE PROBLEM: WASTED MATERIAL The National Ready Mix Concrete Association (NRMCA) estimates 3%-5% of ready-mix concrete deliveries in the U.S. are rejected at the job site for various reasons, such as not meeting specifications. Sometimes, a project simply has leftover ready-mix concrete. The industry has a high rate of wasted material and that is costly. SOLUTION NO. 1: EMBRACE AUTOMATION The VERIFI in-transit concrete management system from GCP Applied Technologies was developed to overcome these pain points. The system uses sensors installed on ready-mix trucks
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to collect real-time data to monitor, measure, and manage concrete properties while the concrete is in transit to the job site. The data is transmitted from on-board computers that communicate with the cloud every 15 seconds, making the data accessible on phones, tablets, and laptops. The VERIFI system offers a new level of concrete quality control and helps increase product consistency from one truck to the next — increasing jobsite efficiency and minimizing costly project delays. Using these data tools conserves materials by delivering concrete that consistently meets specifications, thereby avoiding rejected loads. An added benefit that the VERIFI system provides is increased fuel efficiency. About 23% of fuel in a concrete delivery is used for high-speed drum rotations that mix the concrete. Traditionally, the truck driver has to determine the timing of rotations, using minimal information about concrete consistency or fuel efficiency. In contrast, real-time data from the VERIFI system gives the driver instructions on the optimal number and timing of rotations. Early data suggests that the number of high-speed revolutions can be reduced by 10%, representing significant cost reductions.
SOLUTION NO. 2: RECYCLE WASTE There is also an opportunity to significantly reduce concrete waste via a new patent-pending technology. GCP has developed the CLARENA RC40 additive, which makes it easy to recycle and reuse returned concrete. Instead of having to discharge returned concrete out of the drum and find some way to dispose of it, producers simply add the admixture into the drum. This converts returned, unused plastic concrete into a hardened, granular state that can be reused in fresh concrete as a partial replacement for fine and coarse aggregate. This granular material can also be used as a high-quality compacted fill material for end uses such as road base. The technology offers numerous economic as well as environmental benefits, including: • Conserving raw materials = money savings • Keeping reduced concrete out of landfills The concrete industry is undergoing its own technological revolution. These new innovations free ready-mix operations from numerous constraints that have long been a way of life. These solutions are rapidly becoming an important asset across the entire concrete production process. Forwardthinking producers are realizing tremendous improvements in efficiency, accuracy, and sustainability.
For more information on VERIFI, visit ForConstructionPros. com/21139290.
www.ForConstructionPros.com/Concrete
8/6/20 9:26 AM
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www.clevelandbrothers.com Murrysville, PA 844-569-9650
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Foley, Incorporated www.foleyinc.com Piscataway, NJ 732-885-5555
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H.O. Penn Machinery www.hopenn.com Poughkeepsie, NY 844-CAT-1923
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www.miltoncat.com Milford, MA 888-347-3449
© 2020 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Yellow”, the “Power Edge” and Cat “Modern Hex” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. www.cat.com / www.caterpillar.com
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SPECIFICATION GUIDE: VIBRATING EQUIPMENT
5
VIBRATING EQUIPMENT
A compilation of technical information when choosing your next concrete vibrator. 1. OZTEC BP-50A BACKPACK AND PATENTED RUBBERHEAD The Oztec BP-50a Backpack Vibrator’s rugged design is built for jobsite durability and easy maintenance. Utilizing Honda gasoline engines, coupled with a “speed up” transmission, vibrator heads develop 12,000 vpm and never drop below 10,000 vpm. ForConstructionPros.com/21024619 Model
Size
Weight (lbs)
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
12,000
2.5
7’-21’
8-21 lbs.
3/4” - 2.5”
Round or Rubberhead
Gas
2. OZTEC ELECTRIC MOTORS Oztec Electric motors are manufactured to exacting specifications to withstand the rough day-today abuses associated with construction sites. Lightweight, compact and fitted with comfortable adjustable shoulder strap, this one man power unit will speed through the stiffest concrete. ForConstructionPros.com/21139403 Model
Size
Weight (lbs)
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length)
Flexible Shafts (Weight - lbs.)
Head Diameter (Inches)
Head Configuration: Round or Square (Hybrid)
Power (Electric or Gas)
1.2 OZ / 1.8 OZ / 2.4 OZ / 3.2 OZ
n/a
12 / 16 / 17 / 22
12,000
1.25 / 1.75 / 2.25 / 3.25
2’-21’
2-21 lbs.
3/4” - 2-3/4”
Round or Rubberhead
Electric
3. OZTEC RUBBERHEADS LINE Oztec Electric motors are manufactured to exacting specifications to withstand the rough day-to-day abuses associated with construction sites. Lightweight, compact and fitted with comfortable and adjustable straps. Dimpled construction sends strong shock waves off the entire length of the head, with a larger radius of action, producing denser concrete with less voids to patch. ForConstructionPros.com/21105025
Model
Size
Weight (lbs)
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length)
Flexible Shafts (Weight - lbs.)
Head Diameter (Inches)
Head Configuration: Round or Square (Hybrid)
Power (Electric or Gas)
Rubberhead
1-1/8” / 1-1/2” / 1-7/8” / 2-1/2” / 2-3/4” / 2-3/4” Short
1.75 / 4 / 4.75 / 8 / 10 / 6
12,000
n/a
2’-21’
2-21 lbs.
1-1/8” - 2 3/4”
Rubber Coated
Gas or Electric
4. ALLEN POWER VIBE SERIES VIBRATORS The Power Vibe and Power Vibe Pro concrete vibrators are hand-held gasoline powered vibrators. Both are lightweight but powerful and provide excellent consolidation of concrete. ForConstructionPros.com/20971167 Model
Size
Weight (lbs)
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 Vibe Pro
2’ x 6” x 6”
25
10,000
GX35 cc Honda
2’
10 lbs.
2”
Round
Gas
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8/6/20 9:54 AM
5. WACKER NEUSON ACBe BACKPACK CONCRETE VIBRATOR The ACBe cordless, portable backpack concrete vibration system is suited for the consolidation of thick interior concrete slabs with and without reinforcing steel. ForConstructionPros.com/21123394 Model
Size
Weight (lbs)
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length)
Flexible Shafts (Weight - lbs.)
Head Diameter (Inches)
Head Configuration: Round or Square (Hybrid)
Power (Electric or Gas)
ACBe battery backpack
11.7” x 9.3” x 22”
15.2 w/o battery and 35 with
12,000
2.5
5’-10’
8-21 lbs.
1.5”-2.3”
Round
Electric-battery
6. WACKER NEUSON RECONFIGURED INTERNAL CONCRETE VIBRATOR With its quick connect coupling, the Wacker Neuson IRFUflex High Cycle Concrete Vibrator offers maximum flexibility and ease of use. The modular IRFUflex system enables the exchange of a variety of vibrator heads in only a few simple steps, allowing the operator to be prepared for any situation. An integrated frequency converter and high-cycle technology provide outstanding concrete consolidation results. ForConstructionPros.com/21046370 Model
Size
Weight (lbs)
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length)
Flexible Shafts (Weight - lbs.)
Head Diameter (Inches)
Head Configuration: Round or Square (Hybrid)
Power (Electric or Gas)
IRFUflex
16 x 3.5 x 3.5”
20.5
12,000
2.5
16.5-50’
15-50 lbs.
1.38” - 2.5”
Round
Electric 120V
7. WACKER NEUSON HMS SERIES FLEX SHAFT VIBRATOR MOTORS The HMS series offers flexibility and economic efficiency. These high-frequency, flexshaft internal vibrators can be adapted to every type of application. Heads and shafts can be easily combined and rapidly exchanged to match the right equipment to the job. Unique hybrid heads offer optimum concrete consolidation and movement. ForConstructionPros.com/12239679
Model
Size
Weight (lbs)
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length)
Flexible Shafts (Weight - lbs.)
Head Diameter (Inches)
Head Configuration: Round or Square (Hybrid)
Power (Electric or Gas)
M2500/SM3S/H35HA HMS Modular Head-motor-shaft
12 x 6 x 9”
M2500 motor/ 11.9
14,000 in air
2.5
1.5’-30’
3.3-33 lbs.
1”-2.6”
Both
Electric
8. 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. Capable of powering a flex shaft in excess of 20 ft. in length but typically used with shafts in the 6- to 10-ft. range. The lightweight fiberglass frame features multi-point adjustment straps for maximum comfort and weighs only 29 lbs. ForConstructionPros.com/21015902
Model
Size
Weight (lbs)
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length)
Flexible Shafts (Weight - lbs.)
Head Diameter (Inches)
Head Configuration: Round or Square (Hybrid)
Power (Electric or Gas)
Concrete Vibrator GBPH25 Backpack Vibrator
N/A
29
12,000
2.5
5’-20’
5-62 lbs.
13/16”, 1.25”, 1.5”, 1.75”, 2”, 2.5”
Round
Gas
www.ForConstructionPros.com/Concrete
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CONCRETE CONTRACTOR 29
8/6/20 9:55 AM
SPECIFICATION GUIDE: VIBRATING EQUIPMENT 9. NORTHROCK PRO 2+ CONCRETE VIBRATOR
1
The Northrock 2+ (2 1/2 hp) vibrator motor’s cast aluminum housing dissapates heat quickly and the wraparound frame with rubber shock mounts protects it from falls. ForConstructionPros.com/21015896
Model
Size
Weight (lbs)
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length)
Flexible Shafts (Weight - lbs.)
Head Diameter (Inches)
Head Configuration: Round or Square (Hybrid)
Power (Electric or Gas)
Pro 2+
12” x 8” x 8”
17
10,00012,000
2.5
2’-30’
1 lb./ft.
3/4”-2 1/2”
Round
Electric
10. MINNICH 50 CC GAS-POWERED BACK PACK CONCRETE VIBRATOR The Minnich Manufacturing 50 cc gas-powered back pack concrete vibrator offers outstanding mobility, reliable performance, superior comfort, and reduced fatigue during concrete consolidation. Features include: • A removable throttle assembly which enables operators to relocate the throttle for easy and comfortable operation. • A Honda GX50 general-purpose engine that offers high output and light weight. • An ergonomically designed, fully adjustable harness. ForConstructionPros.com/21102526
Model
Size
Weight (lbs)
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length)
Flexible Shafts (Weight - lbs.)
Head Diameter (Inches)
Head Configuration: Round or Square (Hybrid)
Power (Electric or Gas)
50 CC Back Pack Vibrator
17” x 10” x 24”
20.5
5,000-9,500
2
2’-21’
N/A
N/A
Round
Gas
W I N C H E S W I N C H E S
Y INDUSTR RUCTION ST N O C E TH HES FOR TY WINC SPECIAL
BLOOM MANUFACTURING, INC. Custom Engineered Solutions Since 1910 Independence, IA 50644, USA | bloommfg.com P: 319-827-1139 | 800-394-1139 | F: 319-827-1140
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8/6/20 9:55 AM
11. MINNICH STINGER ELECTRIC FLEX SHAFT CONCRETE VIBRATOR
The Minnich Manufacturing Stinger concrete electric flex shaft vibrator is lightweight, durable and versatile. Features include: • A standard quick disconnect that adapts to the vibrator shafts and heads of many other manufacturers. • A durable protective frame that extends vibrator life with urethane end caps. • A more compatible speed range of vibrations per minute to meet today’s concrete placement challenges. Each model meets Occupational Safety and Health Administration (OSHA) A 29 CFR 1910.95 standards.
ForConstructionPros.com/20986167
OR
Model
Size
Weight (lbs)
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length)
Flexible Shafts (Weight - lbs.)
Head Diameter (Inches)
Head Configuration: Round or Square (Hybrid)
Power (Electric or Gas)
Stinger Flex Shaft Concrete Vibrator Motor
14.5” x 7.5” x 7.5”
14.5
11,00013,000
2.5
2’-21’
N/A
3/4, 1, 1 3/8, 1 3/4, 2, 2 1/2
Round
Electric
le
c
12. VIBCO US-450T HIGH FREQUENCY ELECTRIC VIBRATOR
The US-450T offers high frequency in a single-phase unit with a low amperage draw. It can be plugged into an outlet or it can be operated from a field generator. All US Series units are speed and force adjustable, totally enclosed, and rated for intermittent operation. ForConstructionPros.com/10879769
Model
Size
Weight (lbs)
Vibrations (rpm)
Power (hp)
Flexible Shafts (Length)
Flexible Shafts (Weight - lbs.)
Head Diameter (Inches)
Head Configuration: Round or Square (Hybrid)
Power (Electric or Gas)
US-450T
4-7/8 (124mm) x 8-1/4 (210mm) x 4-3/16(106mm)
12.5
N/A
N/A
N/A
N/A
N/A
N/A
Electric
Systems are air-powered machines used in drastic concrete removal jobs creating rough surface and removing up to a 1/4” per pass.
DESIGNED FOR AGGRESSIVE CONCRETE REMOVAL AND ROUGHENING SURFACES 4” THICK CYLINDER HOUSING
CD-3 Part# 63200
CD-5 Part# 63100
Heavy framework to create powerful crushing impacts
LIFTING BAIL
LEVEL
Creates sturdy lifting point
High spots, uneven joints, concrete gutters
VACUUM PORT
TEXTURE
Captures a high volume of dust
Concrete bond texture for overlays. Eliminate slip hazards.
DUST SKIRT
REMOVE Concrete surfaces, sidewalk trip hazards, dilapidated surface materials
Retains large particles and creates seal on ground for vacuum
edcostore.com • 800-638-3326• sales@edcostore.com • edcoinc.com
www.ForConstructionPros.com/Concrete
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REHABILITATION
»
BY SEAN O’KEEFE
RADIANT HEAT SYSTEM Gets Boost from Molded Polystyrene Rigid Insulation
D
aniel Morak is a builder at heart. From the commitment and camaraderie, to the challenges and opportunities, there’s nothing he doesn’t love about seeing construction come to life. Morak served in the U.S. Army for 23 years before retiring as a NonCommissioned Officer in Charge of Battalion Operations at Fort Bragg. Now in his second career as a Quality Assurance Construction Representative for the U.S. Army Corps of Engineers (USACE), he is overseeing projects of many scales and complexities. “Seeing a team transform a piece of ground from nothing into a building is
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thrilling,” says Morak, who describes his current role as a jack of all trades, master of none. While his Army background was in soil compaction and earthwork, since joining the USACE in 2015, he has led projects ranging from simple duct banks to technology-infused buildings. The USACE is a federal agency under the Department of Defense overseeing a wide range of public infrastructure across the U.S. and around the world. Though most often associated with maintaining dams, canals and flood protection infrastructure, the USACE also leads the design and construction management of military facilities where members of the U.S. armed forces train, work and live.
Among the projects the contractor team is overseeing at Fort Carson, the U.S. Army Mountain Post in Colorado Springs, replacing an outdated airfield is the biggest. Photo Credit: U.S. Army
“Our office oversees construction and inspection of critical infrastructure,” Morak says. “We spend public money wisely by making sure contractors deliver projects as drawn and specified. Our job is to ensure our military is getting the quality they need and richly deserve.” FORT CARSON PROJECTS Among the projects Morak and the USACE team are overseeing at Fort
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8/6/20 10:03 AM
Royse City, TX. IHC has a long history of completing federal projects for agencies such as the Department of Defense, Federal Aviation Administration, as well as state departments of transportation, counties and cities on concrete paving projects of every sort. Cameron Thompson is the superintendent leading the work at Fort Carson. He’s spent his entire career with IHC, building a ground-up
understanding of the means, methods and execution of high-stakes civil construction while working on airfields, highways, roadways and structures. Thompson takes a lot of pride in the work he does and the teams he leads. “I love the people, the process, the high expectations and seeing the results when everything comes together,” he says of his passion for the work and responsibilities at IHC.
Carson, the U.S. Army Mountain Post in Colorado Springs, replacing an outdated airfield is the biggest. Originally laid in the 1950s, much of Butts Airfield had long exceeded its useful purpose and the Army wanted a new, larger airfield along with more modern support facilities to service and store aircraft. “In total, the airfield rehabilitation covers about 14 acres of concrete,” Morak says. Beginning with demolition and removal of the existing airfield, aprons and hangars followed by compacting, leveling and placing the concrete, Morak has spent most of three years overseeing the airfield’s rehabilitation. “We have poured 72,000 yards of concrete on the airfield and another 4,200 yards inside the attack hangar; a massive job altogether,” he says. Delivering the expected quality within the USACE’s schedule and budget expectations, while working on an active military base has been no small assignment for infrastructure contractor Interstate Highway Construction (IHC). Founded in 1947, IHC is a full service heavy civil contractor serving most of the Midwest, with offices in Centennial and Denver, CO; Owosso, MI and
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REHABILITATION CONTINUED Interstate Highway Construction (IHC)
Installed below the concrete before it is poured, radiant heat incorporates plastic tubing to circulate a hot liquid beneath a floor. The heat within the tubes radiates up through the concrete and is released to warm the surrounding air via convection. A key facet of maximizing the efficient return on investment in radiant heating is controlling the heat’s direction of dissipation. Photo Credit: Interstate Highway Construction (IHC)
MODERNIZED HANGAR Over the last 13 years, Thompson has had several opportunities to work on USACE projects and appreciates a client with exacting expectations. Through a series of previous paving
projects at Fort Carson, Thompson built a relationship with the USACE. Earning trust opened doors, and after years of paving exterior concrete exclusively, IHC was invited indoors to install the concrete floors on the interior of the new attack hangar. Designed to hold six AH-64 Apache attack helicopters, the 142,000-sq.-ft. hangar is first class. Along with modern maintenance shops that didn’t exist in the previous hangar, the building includes secured pre-flight planning rooms, flight operations and support facilities as the newest upgrade to the 4th Combat Aviation Brigade and Butts Airfield. The large, open-span, pre-cast concrete building will see year-round use as an aircraft maintenance facility where military personnel need to be comfortable working even with the massive hangar doors wide open in the winter. “Radiant heating has been built into the hangar’s concrete floor to maintain thermal comfort during the colder months of the year,” Thompson says.
RIGID INSULATION Placed below the concrete before it is poured, radiant heat incorporates plastic tubing to circulate a hot liquid beneath a floor. The heat within the tubes radiates up through the concrete and is released to warm the surrounding air via convection. A key facet of maximizing the efficient return on investment in radiant heating is controlling the heat’s direction of dissipation. The USACE’s design specification called for rigid insulation beneath the tubes and 60 PSI high-density, rigid insulation from Atlas Molded Products was ultimately selected. “A layer of molded polystyrene foam acts as an insulator between the earth and the concrete,” Thompson says of the need to efficiently control how the heat dissipates. As much as 50 percent of a building’s heat loss occurs at the perimeter and slab of the foundation, making a below-grade thermal barrier vital to achieving thermal comfort efficiently in the large, highceiling hangar. Although it was Thompson’s first time personally using molded polystyrene as an underslab insulation, it’s well-known for its capacity to insulate roofs, walls and building foundations in pursuit of high-performance building envelopes on facilities of all sorts. Atlas’ line of architectural insulations provides owners and Originally laid in the 1950s, much of Butts Airfield had long exceeded its useful purpose and the Army wanted a new, larger airfield along with more modern support facilities to service and store aircraft. Photo Credit: Interstate Highway Construction (IHC)
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8/6/20 10:03 AM
Contractors recently completed work on the refurbished Apache Attack Helicopter Hangar at Fort Carson in Colorado Springs. The project included radiant heating built into the concrete floor. Photo Credit: Interstate Highway Construction (IHC)
builders with stable R-values between 4.2 and 4.7 per in. and high compressive strengths ranging from 15 to 60 psi. Molded polystyrene’s ability to quickly dry after wetting conditions facilitates Atlas’ products ability to maintain their established R-Values for the life of the building, which translates to more efficient operations. “The molded polystyrene foam insulation was a really easy product to work with,” Thompson says. The soil was compacted, covered with 1-in. rock, and the rigid foam was laid flat on top of it. “We were able to cut penetrations, notch around pipes, and easily fit it around every angle,” he says. Cost is always a driver in any material selection process. Savvy owners like the USACE understand the necessity of calculating not only first costs, but long-term operations costs into decision making. “The USACE doesn’t sole source any particular products,” Morak says of material procurement. “We do have a Buy American Act, and we use American-made materials wherever possible.” As the finishing touches are being put on the hangar at Fort Carson, Morak and Thompson are pleased with the project’s success. “IHC brought the same effective, efficient, and exacting mentality from their exterior concrete projects to the interior,” Morak says. “We can all take pride in knowing this top-flight facility will soon be in service and a job well done.”
For more information, visit ForConstructionPros. com/21138320.
www.ForConstructionPros.com/Concrete
CONC0820_32-35_OKeefe_J.indd 35
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AUGUST/SEPTEMBER 2020
CONCRETE CONTRACTOR 35
8/6/20 10:03 AM
BY GIGI WOOD, EDITOR
SMARTFLOOR POWER TROWEL CUTS DOWN POLISHING TIME AT FLORIDA CHURCH 36 CONCRETE CONTRACTOR
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Pastor Josh Moore assists Roy Mathis of GranQuartz during the polishing process.
I
n May, members of a small, but growing congregation on a tight budget in Pensacola, FL were trying to polish the church floors. After 14 days with a rented cup wheel, they decided it was time to reach out to the professionals. They talked with their distributor, Roy Mathis of GranQuartz in Florida, who called in Ameripolish for help. Ameripolish stepped in and paid for the project. “It was a pay-it-forward type of thing,” says Frank Erceg, Ameripolish territory sales specialist who assisted with the project. The company also opened the jobsite up to other contractors, so they could see a demo of Ameripolish’s SmartFloor Refinement System and its composite resin abrasives technology.
GLOSSY FLOOR IN FIVE STEPS SmartFloor is an easy-to-use pad system that allows swapping out of pads to the universal Velcro blade holders. The system works on any polishing machine, including power trowels. Typically, the process involves about five simple steps, Erceg says. Each of the five abrasive steps involves two passes of cross hatching. The first abrasive step uses the SmartFloor 00 blades/rings at a 40 grit, followed by densifying. In the next step, the SmartFloor 0 blades/rings are used, equal to 100 grit, then on to the 1 blades/rings for 400 grit. Next is the 2 blades/ rings at 800 grit, followed by the 3 blades/rings at 1,500 grit. Finally, the sealer is used. Cleaning and burnishing is done as needed. When Erceg and lead technician Jason Campbell arrived at
Ensley Church of the Nazarene in Pensacola, they conducted a Mohs (Measure of Hardness Scale) test. The concrete floor was at a 3. While most concrete surfaces are constructed within the 5 to 7 range, and the higher the Mohs rating, the longer the pads will last during a polishing job. At the church, contractors densified the floor twice, grinding it six times, stained it, burnished it, sealed it and burnished it again. “They left us with a floor that looks and feels more like glass than it does concrete,” the church posted on Facebook. “Pictures don’t do it justice; you have to see it in person.” When workers finished the SmartFloor process at the church, the Mohs was at a 5 or 6. “We knew once we got to that point (higher Mohs reading), that it
everything you need for your concrete grinding & polishing project
superabrasive.com
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CONCRETE CONTRACTOR 37
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Initial stages of the church flooring project. Photo Credit: Ameripolish
providing support and the contractors who showed up,” he says. “It was really good for everybody.”
POLISHING TECHNOLOGY
was going to be easier to get a nice DOI (Distinction of Image) shine on the floor,” Erceg says. Once the finish was complete, they had DOI readings taken of the floor. The highest rating was 80 and the lowest was about 73 along the 5,000 square-foot space, he says. They finished in a day. “It turned out to be a really good experience all the way around, from the parishioners helping out and
Lythic Polished Concrete Products offer a complete flooring solution with unique colloidal silica technology. 100% reactive silica ensures the concrete is chemically hardened prior to mechanical polishing. Use Lythic Densifiers, Protectors, and Cleaners for long lasting performance.
Erceg attributes the success of the project to the proprietary formula used to produce the abrasives. “If you wanted to leave the floor in a high DOI range, we've proven it now to where we've consistently hit the 80s and wowed the crowds at World of Concrete and other demonstrations,” he says. A popular feature of the SmartFloor System is the interchangeability of the blade holder. “Whether it's an 8-blade, 10-blade or a 4-blade walk behind, you're able to sit the same abrasive, so you don't have to buy different tooling,” Erceg says. The diamond manufacturing and Lead Pastor Josh Moore of pad size is another key differentiator. Ensley Church “When you see the size of the of the Nazarene pad, it's a large amount of abrasive takes a ride on a power trowel. touching the floor,” he says. The SmartFloor Starter Pack Photo Credit: Ameripolish comes with universal blade holders, five abrasive steps, water kit, shroud, densifier and sealer, Mohs hardness kit and blade carrying crates.
For more information on polishing, visit ForConstructionPros.com/21139707.
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BY DALE NEHLS, NATIONAL SALES MANAGER WALL SYSTEMS, QUIKRETE
»
DECORATIVE CONCRETE
Creating a World of
Fantasy, Fun Through Pre-Blended Stucco
A critical element in creating Pacific Point Preserve, which resembles a fishing wharf along the Pacific Coast, was incorporating a home for the Asian small-clawed otters. Photo Credit: QUIKRETE
here are more than 200 zoos and aquariums, and more than 400 amusement parks that millions of people enjoy visiting. For some it’s the opportunity to pet an exotic animal and for others it’s escaping to an adrenaline-filled fantasy land. Whatever encourages someone to
visit a zoo, aquarium or amusement park, the experience needs to be exciting and authentic. To bring realistic animal habitats to life and build seemingly unimaginable park rides, contractors have turned to advanced formula pre-blended stuccos. The ease-of-use, workability and durability of advanced formula pre-blended stuccos provide
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contractors with the flexibility to deliver trademark features and exhibits at zoos, aquariums and amusement parks. The cohesive and non-sag characteristics of advanced formula preblended stuccos allow the material to be sculpted for extended periods of time. In addition, advanced formula pre-blended stuccos can be pumped long distances
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DECORATIVE CONCRETE CONTINUED One of five LEGOLAND Parks in the world, LEGOLAND Florida added the LEGO World of Chima interactive water ride using 168,000 lbs. of QUIKRETE Base Coat Stucco – Pump Grade in its construction. Photo Credit: VisitCentralFL
After removing the old boulders, Cemrock pneumatically applied 20,000 lbs. of stucco over a wire-mesh frame. Before the material hardened, it was shaped and sculpted by hand. Photo Credit: QUIKRETE
on jobsites without clogging, bleeding and segregation. Fibers and water retention admixtures are also often included in pre-blended stuccos to help prevent shrinkage cracking in the face of
hot, dry and windy weather during the installation process. A specialist in the design, fabrication and installation of artificial and themed environments using sculptable building materials, Cemrock Landscape, Inc. has turned to pre-blended stuccos for some of its most impressive projects. AUDUBON ZOO – NEW ORLEANS Opened in 1914 as part of the Audubon Nature Institute, the Audubon Zoo is
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40 CONCRETE CONTRACTOR
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the 58-acre home to more than 200 animals from across the world. The signature entrance features several life-like elephants and hippos playing on boulders in a large fountain. One of the country’s top wildlife entertainment destinations, the Audubon Zoo upgraded the fountain by replacing the old fiberglass elephants and hippos with bronze versions as well as adding several bronze lions. QUIKRETE Base Coat Stucco – Pump Grade was used to create the lifelike boulders. After removing the old boulders, Cemrock pneumatically applied 20,000 lbs. of stucco over a wire-mesh frame. Before the material hardened, it was shaped and sculpted by hand. Once the material cured, it was stained and colored. By taking these refined and artistic steps, the boulders mimic those found in the Serengeti or the other natural habitats of elephants, hippos and lions. LEGOLAND FLORIDA LEGOLAND Florida is a 150-acre, fullday theme park in central Florida featuring more than 50 family rides, shows, restaurants, shops, botanical gardens and other attractions. One of five LEGOLAND Parks in the world, LEGOLAND Florida added the LEGO World of Chima interactive water ride using 168,000 lbs. of QUIKRETE Base Coat Stucco – Pump Grade in its construction. Cemrock chose the stucco because it was easily sculpted and molded on mesh frames to create realistic stalactites and rocks along the powerful, cavernous water ride. In addition, Cemrock found the stucco to pump exceptionally well so work could be done quickly and efficiently on schedule. Families visiting the park now enjoy a trip through the cartoon World of Chima armed with water
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cannons in an epic adventure to help the hero, Laval the Lion Prince defeat Cragger the Crocodile King. “The stucco adhered well to the armature and was easily molded so the exhibit really looks like a natural habitat,” says Thomas O’Keefe, project superintendent for Cemrock. “In addition, by spray applying the materials we were able to work quickly and efficiently while minimizing waste and rework.” SEAWORLD SAN ANTONIO PACIFIC POINT PRESERVE SeaWorld San Antonio Pacific Point Preserve was designed to teach guests about sea lions, harbor seals and Asian smallclawed otters and how to protect them in their natural habitat. A critical element in creating Pacific Point Preserve, which resembles a fishing wharf along the Pacific Coast, was incorporating a home for the Asian small-clawed otters. Cemrock employed a multi-phased
process using a combination of QUIKRETE Shotcrete MS and QUIKRETE Base Coat Stucco – Pump Grade to transform an old existing exhibit into a new natural habitat. Once the deteriorated exterior of the exhibit was removed and repairs were made to the underlying frame, Cemrock reinforced the foundation with shotcrete. Cemrock then pneumatically applied 196,000 lbs. of stucco over a strategically-placed structural armature before sculpting stone and wood features familiar to Asian smallclawed otters, sea lions and harbor seals. Finally, artisans used colored iron oxide pigments to give the exhibit a truly indigenous appearance. Despite being small and meek in appearance, Asian small-clawed otters average 6.5 lbs. and can be very destructive, so the long-term durability of the exhibit is important. As a result, QUIKRETE Concrete Acrylic Fortifier was mixed into the stucco for increased strength and protection against
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Photo Credit:
For more information on decorative concrete, visit ForConstructionPros. com/21139421.
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continuous salt water. The growing popularity of advanced formula preblended stucco to shape zoos, aquariums, amusement parks and other entertainment attractions extend beyond tradiOnce the tional mix designs. Manufacturers deteriorated like QUIKRETE are deploying exterior of the research and development to cusexisting exhibit was tomize base formulas. removed and repairs Whatever the reason – to were made to the match the look of a Pacific Coast underlying frame, fishing wharf or to shape a Cemrock reinforced mythical water ride – the creative the foundation and artistic possibilities with prewith shotcrete. blended stuccos is endless.
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THE LAST PLACEMENT
Pixabay
»
BY BRAD HUMPHREY
Shortening ‘Time Wastes’ on the Job
W
ith all of our “re-start” reasons, some due to normal seasonal start-ups and some imposed on us thanks to the COVID19, it’s about that time of year when a few of the past time wastes re-introduce themselves into our crews’ work efforts. Lean Construction calls one of their seven wastes, “Waiting,” as one of the biggest costs experienced by contractors. When I speak of “waiting,” I’m literally suggesting things that can cause our workers to wait, including: • Equipment breakdown • Employees late to work • Gassing up vehicles/putting water in roller • Late delivery of pre-arranged materials • Job-site not accessible or prepared • Owner didn’t unlock premises • Crew waiting for supervisor to return from lunch The reasons for any work delay are numerous. While the reasons can vary from day to day the costs incurred remains painfully consistent. It is easy to state that you can never replace lost time. “Down-time” in construction, for any reason, normally costs you, the contractor, money and is not recoverable from the customer. What are the costs associated with having workers waiting around? Consider a paving contractor who suddenly finds his five-man crew without asphalt to lay. There was a mixup in the directions given to the driver and the crew is standing around for one hour before the material shows up. Let’s do a potential calculation of the costs incurred by the contractor having five workers standing around for one hour. 5 Workers X 1 Hour Waiting = 5 Total Man-Hours Spent Waiting Average Hourly Rate = $30.00 Per Hour (Fully Burdened Rate)
5 Hours X $30.00 Per Hour = $150.00 Our cost for having labor waiting on materials is $150. Are there other costs? That depends on the step in the process. For example, if the crew needed this missing material to finish out a section, then the hour wait might cause there to be a visible seam between the previous pad and the soon to be laid pad. You might think that one mistake costing $150 is no big deal. And you’re right, if this only happened once…in the year. But, that’s not realistic. Another waste of time for workers to experience is due to lack of planning or organizing. Let’s imagine that 10 employees spend about 60 minutes a day looking for “stuff,” like brooms, brushes, tips, directions, cell numbers, hammers, extension cords, rake, spade, safety tape, time cards, etc. Now, consider that your 10 employees, work at an average hourly rate of $30. Let’s calculate the average cost for one year. 10 Employees X 60 Minutes/Day X 300 Work Days/Year = 180,000 Minutes/ Year 180,000 Minutes/Year ÷ 60 Minutes/ Hour = 3,000 Total Man-Hours/Year 3,000 Man-Hours/Year X $30/Hour = $90,000/Year Therefore, by having each employee looking for “stuff” for 60 minutes per day, we can experience $90,000 in fewer profits for the year. While this amount may not be great for some contractors, it is still a cost that is paid due to poor organization and planning. (Some estimates are closer to 90 minutes per day. Office workers can spend up to two hours per day looking for lost files, etc.) Needless to say, we can only imagine what all of the waiting around is robbing from our organization during the course of a year. Contractors must do
O
a better job of not only providing more clear direction and instruction but also involving their workers in learning how to determine direction for themselves. Consider a few techniques below that you can integrate into your own approach: • Develop a Weekly “Look Ahead” Schedule. This tool should identify what jobs will be performed, what resources will be needed, what day the work will be performed, and who will be completing the work. • Conduct Daily “Huddles.” Each day should begin with a short but informational meeting. Huddles should be five to 15 minutes. This also acts as a verbal daily planner. • Job-Cost & Track Performance. Both efforts not only help you to improve performance but also work to keep more workers educated about what they are doing, what they will need to do it, and how they will go about doing it. • Create Job Tools & Materials List. The document should itemize every tool and material needed for the job. • Make Preventive Maintenance a Company Priority. Put all your equipment and vehicles on a preventive maintenance schedule. • “Stage” Your Job-Site at the End of Each Day. Getting the job or work site ready for the next day’s performance will save you time the following morning. So many of the techniques presented in this article are common sense, yet I still find many contractors who allow it. Integrate the techniques shared here into your own leadership.
For more information on reducing time waste, visit ForConstructionPros. com/21132340.
F
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FRO
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