Concrete Contractor February/March 2020

Unique Stamping Technique Replicates White Limestone

22 February/March 2020

THE LEADING TRADE MAGAZINE IN THE CONCRETE INDUSTRY

STATE OF THE INDUSTRY

Rules for Field Testing Concrete 30

2020 16

Innovations in Polishable

OVERLAYS

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New

Come See Us in the Central Hall!

We invite you to stop by our GOMACO booth in the Central Hall at CONEXPO-CON/AGG 2020 to see what it means when we say, “Dedicated to Concrete – Dedicated to You”. GOMACO offers the full range of concrete slipform pavers, curb and gutter machines, placer/spreaders, texture/cure machines and bridge/canal finishing equipment. GOMACO equipment features our exclusive and proprietary G+® control system, created in-house by our software engineers from the wants and needs of contractors paving in the field. We’ll show you the new Navigator controller with a 10-inch touchscreen that allows ground personnel to simply control and view all attachments from one location. We are also introducing our new high-production system for the C-450 cylinder finisher for bridge decks and flat slabs. At the heart of GOMACO equipment is our passion for concrete and our commitment to our customers.

We look forward to visiting with you about your upcoming paving projects and your concrete paving equipment needs.

CONCRETE STREETS AND HIGHWAYS x AIRPORT RUNWAYS x CURB AND GUTTER x SIDEWALKS RECREATIONAL TRAILS x SAFETY BARRIER x BRIDGE PARAPET x BRIDGE DECKS x IRRIGATION CANALS GOMACO CORPORATION IN IDA GROVE, IOWA, USA x 712-364-3347

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WHAT’S INSIDE

February/March 2020 | Issue 2, Volume 20

Departments 4 Editor’s Letter 6 Post-World of Concrete Products 50 The Last Placement

What’s Online

Cover Story

Contractor Uses Robotic Demolition to Topple Vancouver Landmark

16 State of the Industry 2020

JMX Contracting used two Brokk 400 diesel machines and a Brokk 160 electric unit to systematically remove 44 stories in 21 months.

Search: 21110075

Strength in consumer spending and the labor market suggest another strong year ahead, but challenges and new opportunities await.

30 Concrete Field Testing 101

Features 10 Alternative Formwork Solutions that offer an option other than lumber continue to infiltrate the market.

Using the appropriate methods and procedures can prevent costly project delays.

Precast Manufacturer Capitalizes on Safety to Reduce Claims Cost by 79% ATMI Precast recognized a need for new safety protocols and initiatives to manage growing workers’ compensation challenges.

Search: 21113512

34 Riding the Automation Wave 22 Stamped Concrete Replicates White Limestone Indiana contractor Mike Lindsey uses a white-on-white stamping technique to achieve a unique look.

Cloud-based platforms take break machines into the future.

36 Specification Guide: Power Trowels A compilation of technical information when choosing your next power trowel.

42 Polished Concrete Meets Glass A new overlay system uses glass chips, offering the benefits of polished concrete with the look of terrazzo.

46 5 Things to Consider When Selecting an Abrasive There are multiple variables and conditions to be considered when choosing your abrasives.

www.forconstructionpros.com/concrete | February/March 2020 | Concrete Contractor 3

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EDITOR’S LETTER Published by AC Business Media

OSHA SILICA RULE: Where Are We Now?

I

201 N. Main Street, Fort Atkinson, WI 53538 (800) 538-5544 • www.ACBusinessMedia.com

PUBLICATION STAFF

Associate Editor Contributing Writers

n 2016, the Occupational Safety and Health Administration (OSHA) issued its final rule on silica dust exposure.

The goal of the rule was to prevent and eliminate lung cancer and various lung and kidney diseases in U.S. workers by limiting their exposure to respirable crystalline silica.

Respirable crystalline silica consists of small silica particles that are generated by cutting, sawing, grinding, drilling, and crushing materials such as stone, rock, concrete, brick, block and mortar.

Since enforcement of the rule went into effect for the construction industry in 2017, the concrete sector in particular has come a long way to ensure compliance while protecting its workforce from inhaling the silica dust created during operations. But, there is still room for improvement.

According to the National Safety Council, respiratory protection violations were the fifth most cited violation in 2019, with 2,540 violations. Most companies were cited for not providing employees with a medical evaluation before using respirators or for not having a respiratory protection program in place.

Earlier this month, OSHA established a revised National Emphasis Program (NEP) to further identify and reduce or eliminate worker exposures to respirable crystalline silica. The NEP targets specific industries expected to have the highest numbers of workers exposed to silica and focuses on Facebook.com/ ConcreteContractor

Advisory Board

Amy Wunderlin, Associate Editor AWunderlin@ ACBusinessMedia.com

enforcement of the new silica standards.

Changes made to the NEP include: • Revised application to the lower permissible exposure limit for respirable crystalline silica to 50 micrograms per cubic meter as an 8-hour timeweighted average • Updated list of target industries from which OSHA will develop randomized establishment lists of employers in their local jurisdictions for targeted inspections • Compliance safety and health officers will refer to current enforcement guidance for RCS inspection procedures • All OSHA regional and area offices must comply with this NEP, but they are not required to develop and implement corresponding regional or local emphasis programs • State plans must participate because of the nationwide exposures to silica With OSHA revisiting its rules on silica dust exposure, now is a great time to take a look at your safety protocols and put a plan in place to make the jobsite a safe place for all your employees.

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Kim Basham KB Engineering Cheyenne, Wyo.

Jim Cuviello Cuviello Concrete Polished|Stained|Crafted Stevensville, Md.

Jim Baty Concrete Foundations Association Mt. Vernon, Iowa

Chris Klemaske T.B. Penick & Sons, Inc. San Diego, Calif.

Ins

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PO Box 3605, Northbrook, IL 60065-3605, Phone: (877) 201-3915 Fax: (847) 291-4816 • circ.ConcreteContractor@omeda.com REPRINTS Sean Dunphy, (800) 538-5544 , sdunphy@ACBusinessMedia.com LIST RENTAL Jeff Moriarty, SVP, Business & Media Solutions Infogroup, Phone: (518) 339-4511 Email: jeff.moriarty@infogroup.com AC BUSINESS MEDIA

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CONCRETE CONTRACTOR (USPS 021-799, ISSN 1935-1887 (print); ISSN 2471-2302 (online) is published 7 times a year: January, February/March, April/May, June/July, August/September, October/November and December by AC Business Media, 201 N. Main Street, Fort Atkinson, WI 53538. Printed in the U.S.A. Periodicals postage paid at Fort Atkinson, WI, and additional entry offices. POSTMASTER: Send address changes to Concrete Contractor, PO Box 3605 Northbrook, IL 60065-3605 February/March 2020, Issue 2, 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).

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4 Concrete Contractor | February/March 2020 | www.forconstructionpros.com/concrete

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PRODUCTS

World of Concrete PRODUCT REVIEW A compilation of new products from the big show.

GatorBar Glass

Neuvokas Corp, a composite rebar manufacturer, introduces GatorBar Glass, its initial GFRP rebar product. GatorBar Glass offers the lowest cost composite rebar with improved handling by virtually eliminating slivers. It is 100% made in USA, meets all ASTM 7957 specifications, and provides a guaranteed tensile strength 4X greater than grade 40 steel rebar.

GatorBar Basalt and Glass are composite rebar products that dramatically reduce material, labor, transport and handling costs, while providing better crack control compared to steel rebar.

• Zero-rust rebar solution in normal, high chloride concrete and corrosive environment applications • Produced with an advanced, sliver reducing, polyester-free resin system ForConstructionPros.com/21112068

42 M5 XXT Concrete Pump

Liebherr's 42 M5 XXT truck-mounted concrete pump features the Powerbloc drive unit with all hydraulic switching and measuring elements completely integrated.

• 5 piece multi-folding mast • XXT outrigger support system • Powerbloc powered by a semiclosed hydraulic circuit • Unfolding height of under 28.2 ft.

• Vertical reach: 135 ft.

ForConstructionPros.com/21113001

New Makita XEC01 Cordless Concrete Cutter Makita’s new XEC01 cordless 9-in. power cutter eliminates the hassles of gas in a cordless concrete cut-off saw.

• 18V X2 (36V) LXT technology allows for lower noise and reduced maintenance • Zero emissions • Compact and light weight • Integrated water delivery with flow adjustment knob continuously feeds water for OSHA Table 1 Compliance ForConstructionPros.com/21114289

GOMACO High-production Screed

This high-production truss-mounted screed for paving bridge decks, flat slabs and floors can advance up to 4 ft. in a single pass, and can be used to finish city streets, concrete floors, bridge decks, tunnels and canals at widths up to 104 ft.

• Mounted to the C-450 truss system and is instrumental for the optional 3D package to finish to a 3D design model • 5.7-ft.-long leading auger with a high-production strike-off action reduces the number of puddlers needed out front • 5-ft.-long finishing cylinder directly behind the auger compacts and finishes concrete in a single pass • 6-ft. trailing screed provides final finish to concrete surface with a unique vibratory system ForConstructionPros.com/21112378

Lavina 16E Compact Grinder from Superabrasive

L16E is a new lightweight and compact grinder in the Lavina Elite Series by Superabrasive. It is a forced planetary, variable speed machine with three 7-in. heads. It runs on single phase 115V, making it convenient for use on a variety of projects, commercial and residential. It has a foldable frame and can be separated in two pieces for easy transportation and storage.

ForConstructionPros.com/21107480

ScanDust 9000 World Series

Scanmaskin's ScanDust 9000 World Series dust collectors feature a patented, built-in pre-separator to separate dust into two stages and provide up to 90% pre-separation.

• Electric or propane versions • 32 Teflon coated sock filters and two HEPA 14 filters with 99.995% filtration rate • Electric version equipped with frequency control to adjust power and speed • Filter guard warns when filters need cleaning • Longopac bag system • Height-adjustable cyclone • Solid rear wheels and 200 mm large swivel wheels ForConstructionPros.com/21113859

Sulzer Launches New COX Dispensers

The COX ElectraFlow family of battery-powered dispensers has introduced two new members.

The ElectraFlow Dual Ultra is ideal for dispensing two-component adhesives in a 1:1 ratio, while ElectraFlow Plus provides an advanced tool for operations that require one-component cartridges.

ElectraFlow Plus features a trigger lock that prevents accidental material discharge and a variable speed trigger.

ElectraFlow DualUltra meanwhile has a practical cartridge locator to retain the cartridges in their correct position.

• Powerful cordless technology from the latest Bosch Professional 18V lithium-ion range of batteries/chargers • Extended runtime and service life • Battery compatibility with a wide selection of existing Bosch power tools ForConstructionPros.com/21110835

Alu unm and elev

>>

6 Concrete Contractor | February/March 2020 | www.forconstructionpros.com/concrete

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A ONE-OF-A-KIND LIGHTWEIGHT DRIVE-IN SCREED

• Upper Deck • Residential • Slab-On-Grade • 3D Surfaces

New from Ligchine, the SPIDERSCREED™ addresses the common issues of drive-in screeds such as weight, power, navigation, and leveling capabilities.

Aluminum frames, high-speed electric actuators, unmatched navigation with the Versa-Drive™ system, and Ligchine’s patented machine leveling system elevates the SPIDERSCREED™ into a class of its own.

>> See more at www.ligchine.com sales@ligchine.com | 812-903-4500

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PRODUCTS ChemMasters Barracuda Triple Action Lubricant

HDX780 Hydra-Drive Extreme Riding Trowel

ChemMasters Inc.'s new industrial multi-purpose penetrant/lubricant Barracuda Triple Action Lubricant has a proprietary formulation that penetrates, cleans and protects metal.

• Can be used as a water protectant.

• Ideal for use on stamping blanks and dies for aluminum or steel coil or sheet stock.

• Rust proofs machine tables, chucks, ways, gears bushings or tools susceptible to corrosion from high humidity.

• Available in 11 oz. aerosol can, 1 gal. jugs, 5 gal. pails or 55 gal. drums.

ForConstructionPros.com/21112854

Allen Engineering's HDX780 Hydra-Drive Extreme Riding Trowel is designed for high volume flatwork concrete.

• Dedicated panning/finishing modes • Digital readouts of fuel levels and diagnostics • 18-gal. fuel tank • Turbo charged 50-hp Hatz 4H50TIC liquid-cooled, Tier 4 Final diesel engine • Premium Bosch-Rexroth Hydraulic system • Intelli-drive system allows the engine and the hydraulics to communicate • Bi-ligual digital display shows engine diagnostics (temp, RPM, oil pressure, warnings, etc).

ForConstructionPros.com/21113035

CC30 Concrete Claw

Vacuworx Introduces PHD Portable Vacuum System

Kubota's CC30 Concrete Claw is used for digging and removing large sections of concrete floors, driveways, sidewalks and other large slabs.

• Universal quick-attach hitch fits a variety of laders • High strength T1 steel side panels resist bending forces • Reinforced side panels • Performance matched with Kubota SSV and SVL Series ForConstructionPros.com/21113973

With smart features like a remote control, lithium battery and dual pump design, the PHD is ready to prove how it can help contractors work faster, safer and smarter.

• 12V 30 amp/hour rechargeable LFP (Lithium Iron Phosphate) battery is designed to provide longer run time and overall longer battery life.

• Two dual-stage vacuum pumps to build vacuum faster.

• Designed to absorb vibration from the pump for quiet operation.

• Inline filter protects the system from dust and debris.

• Weighs 25 lb., yet generates enough power to lift up to 2,500 lbs.

ForConstructionPros.com/21113999

Stat-Rez ESD Nano from APF Polymer Surfaces 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.

For more information, visit www.lythic.com

www.solomoncolors.com • www.lythic.com 800.624.0261

Infused with ICP’s Nanowise Technology, single-wall carbon nanotubes utilized in Stat-Rez ESD Nano allow for performance features previously unobtainable in traditional antimony tin oxide ESD systems. These nanotubes create elongated tubes that produces an intertwined network within the coating, eliminating room for hot spots while providing unmatched strength. This network also prevents settling within the coating extending shelf life.

ForConstructionPros. com/21114707

TyBot an Autonomous Rebar-Tying Robot

TyBot is an autonomous rebar-tying robot that can augment and reduce labor need for a rebartying project.

• Autonomous navigation of its working area (no pre-mapping or calibration required) • Identifies and ties rebar intersections • Runs day or night, rain or shine, without breaks or injuries • Doesn't impede other construction equipment or infrastructure • Leased option staffed with a trained and dedicated quality control technician ForConstructionPros. com/21114729

8 Concrete Contractor | February/March 2020 | www.forconstructionpros.com/concrete

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Hilti Tracefast Smart Fasteners Document Anchor Installations

Hilti launched connected fasteners, enabling unique identification and digital documentation of fastener installations on the jobsite. Documenting every anchor, screw and bolt installed by hand can be time consuming and inefficient. Hilti’s Tracefast technology provides specifiers and contractors with an easy-to-use, more productive solution. A data matrix code (DMC) makes every fastener uniquely identifiable and traceable. Using the Hilti Connect App, scan the code on the fastener with your smart phone and view installed fastener details. Tracefast leverages the internet of things and provides a new level of control and digital access to relevant setting instructions, training and inspection documents and certifications.

ForConstructionPros.com/21114534

23kW 480V 3-Phase Generator

Makinex introduces the world’s smallest 23kW 480V threephase generator at less than one-third the size and weight of comparable towable and skid generators.

• Permanent magnet brushless alternator technology with completely independent circuits for 120V and 480V • Run single-phase and three-phase equipment simultaneously • Weighs 410 lb.

• Fits through doorways and can safely be taken in internal/external elevators ForConstructionPros.com/21114611

XR1347-C, XR1547-C and XR1555-C Rough Terrain Telehandlers Xtreme Manufacturing's rough terrain telehandlers are electric over hydraulic and feature a modular cab design that can switch from open to enclosed with an optional kit.

• Cummins 3.8L 120-hp Tier 4 Final engine • Available with either foam filled or solid tires • Additional air vents in cab for increased air conditioning ForConstructionPros.com/21113854

Stronghold Quick-Switch System for Dropped Object Prevention

Pure Safety Group (PSG) launched the Stronghold Quick-Switch Total Tether System for the prevention of dropped objects during work at height.

The Quick-Switch system gives workers the flexibility to use multiple tools at their work areas and switch tools, all while keeping them connected through a patented combination of keys, links and anchors.

ForConstructionPros. com/21112847

MEET BROKK 70 THE NEW MINI SUPER HERO Packed with demolition power, faster than ever and extremely compact. The BROKK 70 is the perfect solution for safe and efficient demolition in very confined spaces.

Festival Hall Booth F101901 Brokk Inc. | Monroe, WA | 1-360-794-1277 | info@brokkinc.com | www.brokk.com

www.forconstructionpros.com/concrete | February/March 2020 | Concrete Contractor 9

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FOUNDATIONS & WALLS

By Amy Wunderlin

An Alternative to Lumber

FORMWORK

Solutions that offer an option besides lumber continue to infiltrate the market, saving contractors time, money and manpower.

W

ood has been the concrete contractor’s formwork of choice for years.

It’s relatively inexpensive and easy to understand, light weight, can easily be cut to size, and is easy to replace and dismantle.

However, lumber formwork also has its disadvantages. It has limited usage and cannot be reused from one job to the next. Wooden formwork also been

known to absorb water from concrete when dry, reducing the strength in concrete structure. On the flipside, lumber with too much moisture can compress wet concrete and cause cracks when shrinking occurs.

These challenges have resulted in hundreds of formwork alternatives— from steel, aluminum, manufactured timber, plywood, plastics and fabric— that claim to offer the trifecta: savings in time, labor and money.

Formwork is a crucial element to concrete construction, though, so it is a decision contractors should not take lightly. The right choice can greatly affect the schedule, labor requirements, quality and total cost of a project, says Michael Schaeffer, senior U.S. product manager with Doka USA. “Formwork, the temporary or permanent molds used to hold wet concrete until it sets, is a crucial element in concrete construction. Just as

Above: The use of Rapid Form Brackets on the construction of a four-story office building eliminated the need for about 720 two by fours at a cost of $4,800. In addition, the contractor estimates a labor savings of $26,800.

Photo Credit: Innovative Concrete

Below: Made of high-density polyethylene fabric, Fab-Form markets its products as a green replacement of lumber and plywood for forming concrete footings.

Photo Credit: Fab-Form Industries

10 Concrete Contractor | February/March 2020 | www.forconstructionpros.com/concrete

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Finisher Specialty Commercial/Industrial Technician Strength Testing Technician Laboratory Testing Technician Aggregate Testing Technician Aggregate/Soils Base Technician Concrete Construction Construction Special Inspector Concrete Quality Technical Manager Concrete Transportation Special Inspector Tilt-Up Supervisor Tilt-Up Technician Shotcrete Nozzleman Shotcrete Nozzlemanin-Training Masonry Field Testing Technician Masonry Laboratory Testing Technician Adhesive Anchor Installer Field Testing Technician Flatwork Finisher Specialty Commercial/Industrial Finisher Specialty Commercial/Industrial Technician Strength Testing Technician Laboratory Testing Technician Aggregate Testing Technician Aggregate/Soils Base Technician Concrete Construction Special Inspector Field Testing Concrete Quality Technical Manager Concrete Transportation Special Inspector Tilt-Up Supervisor Tilt-Up Technician Shotcrete Nozzleman Shotcrete Nozzleman-in-Training Masonry ch tyFlatwork Finisher nician Masonry Laboratory Testing Technicia Adhesive Anchor Installer Field Testing Technician Flatwork Finisher Specialty Commercial/Industrial Finisher Specialty Commercial/Industrial Technician Strength Testing Technician Laboratory Testing Technician Aggregate Testing Technician Aggregate/Soils Base Technician Concrete Construction Special Inspector Base Technician Transportation Special Inspector Concrete Transportation Special Inspector Tilt-Up Supervisor Tilt-Up Technician Shotcrete Nozzleman Shotcrete Nozzleman-in-Training Masonry Field Testing Technician Masonry Laboratory Testing Technicia Adhesive Anchor Installer Field Testing Technician Flatwork isher Shotcrete her Commercial/Industrial Finisher Specialty Commercial/Industrial Technician Strength TesNozzlemanian Laboratory Testing Technician Aggregate Testing Technician Tilt-Up Soils Base Technician Concrete Construction Special Inspector Associate Concrete TransSupervisor ial Inspector Concrete Transportation Special Inspector Tilt-Up Supervisor Tilt-Up Technician Shotcrete Nozzleman Shotcrete Nozzleman-in-Training Masonry Field Testing Technician Masonry Laboratory Testing Technician FF vvv Adhesive Anchor Installer Field Testing Technician Flatwork ty Strength Specialty ialtyCommercial/IndustrialFinisherSpecialtyCommercial/IndustrialTechnicianStrengthTestingTechnician Concrete Testing Technician Aggregate Testing Technician Aggregate/Soils Base Technician ete Construction Special Inspector Concrete Quality Technical Manager Concrete nician Special Special Inspector Tilt-Up Supervisor Tilt-Up Technician Shotcrete Nozzleman Field Testing otcrete Inspector an-in-Training Masonry Field Testing Technician Masonry Laboratory TTesting Technician The American Concrete Institute offers nearlyCommercial/Industrial Adhesive Anchor Installer Field Testing Technician Flatwork Finisher Specialty 30 certification programs to satisfy any Finisher Specialty Commercial/Industrial Technician Strength Testing Technician Laboratory Testing l Tilt-Up Aggregate Testing Technician Aggregate/Soils Base Technician Concrete Construction number of concrete specialties.

Learn how to ecial Technicianssociate Concrete Transportation Inspector Concrete Transportation get your team ACISpecial certified at Special Inspector Tilt-Up Supervisor Tilt-Up Technician Shotcrete Nozzleman ShotAdhesive Anchor concrete.org/certification. in-Training Masonry Field Testing Technician Masonry Laboratory Testing Technicia Installer Anchor Technician Flatwork echnician Flatwork Finisher Specialty Commercial/Industrial Finisher Specialty Aggregate Testingtrial Technician Strength Testing Technician Laboratory Testing TechnicianTechni Testing Technician Aggregate/Soils Base Technician Concrete Construction Special Inspector Concrete Quality Technical Manager Concrete Transportation Special Inspector Tilt-Up Supervisor Tilt-Up Technician Shotcrete Nozzleman Shotcrete Nozzleman-in-Training Masonry Field Testing Technician Masonry Laboratory Testing Technician Adhesive Anchor Installer Field Testing Technician Flatwork Finisher Specialty Commercial/Industrial Adhesive Anchor Installer Industrial cian Strength Testing Technician Laboratory Testing Technician Aggregate Testing Technician Con Aggregate/Soils Base Technician Concrete Construction Special Inspector Concrete Quality T Inspector Tilt-Up SupervisorTransportation Special Inspector Shotcrete Nozzleman-in-TrainingShotcrete Nozzleman Tilt-Up Technician Shotcrete Nozzleman-in-Training Masonry Field Testing Technician Adhesive Anchor Installer Masonry Laboratory Testing Technician Field Testing Technician Flatwork

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FOUNDATIONS & WALLS

Made of steel, the Rapid Form Bracket takes the place of lumber supports in the construction of elevated slabs.

Photo Credit: Innovative Concrete

important is selection of the right formwork,” Schaeffer notes. “Over the years, formwork molds have evolved from traditional job-built timber to pre-engineered systems composed of a combination of steel, aluminum, manufactured timber, plywood and plastics. These advancements in formwork molds have led to increased jobsite production and safety, with less labor, while producing a better-finished product.”

But with so many options, how can contractors ensure they’ve chosen the right one? Schaeffer suggests the following tips to consider when choosing a formwork system: • Is the material you require readily available? Does the supplier manufacture the material, or do they purchase it from another company?

• Can the formwork supplier pre-assemble some or all of the formwork prior to delivery? This can reduce rental cost, save labor requirements and minimize assembly area requirements.

• Does the supplier provide on-site field service to train and reduce the learning curve of the formwork crew?

• How safe is the system to install, use and dismantle? Can the forms easily be climbed and are tie-off points built into the system where required?

• What experience does the firm have with your type of project?

• Does the supplier offer engineering services? Will the supplier provide formwork assembly drawings

specifically for the project or only provide general drawings of the system?

Now let’s look at a few of the newest formwork alternatives on the market.

RAPID FORM BRACKET The Rapid Form Bracket from Innovative Concrete was designed to take the place of lumber supports in the construction of elevated slabs. The bracket is commonly used for work on foundations around a building, when constructing loading docks, or any job involving vertical work.

Made of steel and then powdercoated to keep rust away, the bracket’s inventor Bob Kalbach says it eliminates the labor and costs involved in purchasing, layout, measuring, cutting, constructing and cleaning up after stripping of wood supports. He estimates that the traditional process takes about three times longer than the bracket does.

When a slab is designed to turn down on top of a wall, you have to form the outer edges so that concrete doesn’t go over the top of the wall.

Traditionally, this is done by cutting two by fours that hold the form against the wall. The pieces are layered on top of each other, the form is attached and then everything is braced. Once the concrete is poured, the supports then are removed and thrown away.

“Why are we paying $1,200 for a pallet of wood, cutting it all up and taking these pieces and throwing them

away when we’re done. Not just that, but you have to collect all of that.

Hundreds of pieces collected and then thrown in the dumpster,” asks Kalbach.

The bracket was recently used during the construction of a four-story office building for LifeQuest, totaling 3,675 lineal feet of slab form. The project called for 925 brackets, which saved the company approximately 720 two by fours at a cost of $4,800. In addition, the contractor estimates a labor savings of $26,800.

FABRIC FORMWORK The use of fabric formwork began in the early 20th century with concrete architectural structures. Today, the formwork alternative is slowly gaining momentum in the construction industry as the public’s focus on sustainability grows. The industry is increasingly being asked to address and lower its carbon footprint. While the use of wood and/or metal is not completely eliminated by using fabric, it can be reduced to essential components thereby saving natural resources.

Using fabric formwork, such as a geotextile, offers several additional advantages, according to an article

by Robert P. Schmitz, a registered professional engineer, with more than 35-years’ experience in architecture and structural engineering. Those benefits include: • The possibility to form very complex shapes • Fabric is strong, lightweight, inexpensive and reusable • Improved surface finish and durability due to its filtering action • More efficient and sustainable design because material is placed only where it is needed • Increased freedom of design expression, allowing architects and designers to think beyond the simple prismatic shape

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FOUNDATIONS & WALLS

To be of practical use to the design community, some standardization of systems and guidance are needed for contractors to feel comfortable using flexible formworks.”

Leading the charge for adoption in the construction industry, Richard Fearn, owner and founder of Fab-Form Industries, Ltd., has developed several fabric forming products, including Fastfoot for continuous and spread footings, Fastbag for spread footings, and Fast-Tube for piers and columns.

Made of high-density polyethylene fabric, Fab-Form’s markets its products as a “green replacement of lumber and plywood for forming concrete footings.”

Force Concrete & Masonry Corporation of Piscataway, New Jersey, has been working with Fab-Form for nearly a decade. They recently used the Fastfoot product to form the footings of Rutgers University’s new Health & Athletic Performance Center.

The project had a tight deadline— just six months. Because Force Concrete & Masonry was able to setup huge amounts of formwork before the pour took place, they were able to pour all the concrete in one day, keeping the project on track. In addition, because the fabric prevents the concrete from touching the lumber framework, the lumber framework can be reused and easily stripped, further increasing labor productivity.

“When you strip [the forms], you only remove the lumber framework,” explains Bill Pavlic of Force Concrete & Masonry. “The fabric conforms to the uneven ground, which makes it a lot easier. If you’re using regular forms, you have to go back and patch in the bottom or other spaces.”

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Schmitz notes that fabric formwork does have its disadvantages though, including: • Relaxation can occur due to the pre-stress forces in the membrane • The potential for creep in the geotextile material, which can be accelerated by an increase in temperature as might occur during hydration of the concrete as it cures • The concrete must be placed carefully, and the fabric formwork not jostled while the concrete is in a plastic state “However, until new fabrics are developed, the benefits of using geotextiles far outweighs any disadvantages,” Schmitz writes. “In addition, unless standards and guidelines for use in precast and cast-in-place forming systems are developed, this method of forming concrete will remain a niche market exploited only by those brave and bold enough to challenge the status quo.

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seeing a resurgence in popularity. In fact, before the collapse of the housing market in 2008, many homes were built with ICFs—a type of permanent concrete formwork that create the external wall envelope of a building. The alternative formwork has regained some of that traction in recent years as the popularity of energy efficient and disaster resistant homes and buildings grows.

In the past, single family residential accounted for about 70% of ICF construction compared to about 30% for commercial or multifamily uses, according to a report by the Portland Cement Association (PCA). But, use in larger commercial buildings appears to be a growing market for several reasons. Chief among them is the potential for reducing energy to heat and cool the building.

According to the PCA report, some estimates place the savings at 20% or more. The R-value for a typical ICF is about 20, and the walls can often have

high air tightness 10-30% better than frame-with compatible windows, doors and roof. As a result, assuming a 100year service life, PCA estimates one single-family ICF home has the potential to save about 110 tons of CO2 compared to a traditional wood frame home. “This more than offsets the CO2 associated with the production of the cement used to make the concrete,� the report adds.

Shown here are Nudura Insulated Concrete Forms, which meet the demands of today's buildings, offering an energy efficient and eco-friendly construction option.

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In addition, ICF save natural resources by eliminating the structures wood frame. The forms also often contain recycled materials.

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STATE OF THE INDUSTRY

By Amy Wunderlin mammuth/ iStock / Getty Images Plus

STATE OF THE INDUSTRY

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Strength in consumer spending and the labor market suggest the concrete industry can expect another strong year—though its biggest challenges will also remain.

C

ement consumption is one of the best ways to analyze and predict strength in the concrete industry, and so far, all signs point to another positive year.

While it’s likely that the economy has hit its peak, the industry is still expected to see modest growth at least for the next few years. In its Fall Forecast released in October 2019, the Portland Cement Association (PCA), whose members represents 91% of the U.S. cement production capacity, predicted moderate cement consumption growth of 1.7% in 2020 and 1.4% in 2021.

“The economy doesn't have the zip and the vigor that it had 10 years ago, and so what we're seeing is the economy's now in late stages of economic growth and recovery. That suggests that overall growth is going to start to slow, which is reflected in a slowdown in GDP numbers. It's also reflected in our slow-down in job creation numbers,” explains Ed Sullivan, PCA senior vice president and chief economist.

The pillars of economic strength are consumer spending and the labor market. How either one varies monthto-month gives economists a clear picture of economic health.

“If we see any decay in the job creation numbers that come out monthly, or we see significant changes

in some of the consumer numbers like vehicle sales, that would give us pause and concern,” Sullivan explains.

Right now, however, he says both are doing just fine, adding that not only is the jobs market strong, but wages are also beginning to accelerate slightly, and home prices continue to rise. Add to that prices that are relatively tame in terms of inflation and low interest rates, and Sullivan says you have “a cocktail of really favorable consumer spending attitude.”

“You have a willing and able consumer, so if you’ve got the consumer, the economy’s going to be in fairly good shape,” he adds.

Since releasing the Fall Forecast, Sullivan says that residential construction has gained some strength, indicating cement consumption could be slightly stronger than 1.7% next year.

“We're seeing now in the latest tracking that residential single-family starts could represent as much as a million tons more in cement consumption.

So that's the biggest change I see going forward next year,” he adds.

SKILLED LABOR SHORTAGE TO CONTINUE Even with the backing of a strong economy, concrete contractors should still expect to face a number of challenges this year. Most notable will be the continuing shortage of skilled labor.

“The good news is certainly that the workload is going to be robust, but on the other hand, that means we don’t have all the folks we need in the construction industry,” says Randall W. Poston, senior principal at Pivot Engineers and president of the American Concrete Institute (ACI).

Construction, along with health care and personal care, will account for one-third of all new jobs through 2022, according to the Bureau of Labor Statistics. But, 70% of construction companies nationwide are having trouble finding qualified workers, according to the Associated General Contractors of America.

A strong economy with a low rate of unemployment is one culprit for the labor gap.

“Unemployment is still going to be well below what the natural rate is—somewhere between 3.5 and 3.8 this year—and that suggests that the skill shortage continues for construction,” Sullivan says.

A continued disinterest from America’s youth, however, is the bigger cause of the industry’s ongoing struggle. Organizations such as the National Ready Mixed Concrete Association (NRMCA) and ACI are working to combat this by offering several educational, training and certification programs.

“There's a lot of concern to this day and it has been for many years about the labor shortages in the concrete industry. Drivers are scarce, and they're unpredictable…but the NRCMA is doing a lot of very positive things as far as putting programs in place such as driver training, recruitment and retention to try and help that situation,” says NRMCA President Michael Phillips.

ACI’s focus is on certification, ensuring that those who do enter the

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STATE OF THE INDUSTRY

The growing national debt is one area of concern often ignored, which Sullivan says could have lasting impacts on the construction industry.

Today there is an enormous need to

way to pay for it without adding to this huge deficit, I don’t see it happening,” Sullivan says. “It took from George Washington all the way to Ronald Reagan to generate our first $1 trillion in federal debt, and we’re doing that every year now. The debt is enormous.”

Because of that, Sullivan further emphasizes that “debt is going to play an increasingly important role as we go forward the next four years or so.”

Phillips and the NRMCA’s outlook on infrastructure is slightly more positive, but he too acknowledges that the 2020 election will impact how the federal government moves forward on the issue.

“It's a pretty good forecast for 2020, but there's this thing called an election that's looming at the end of the year—and I think that's obviously the wild card,” he says. “We’re in a state today that’s very pro-business, very regulatory responsible

expand infrastructure but little idea how to pay for it—and the upcoming election further complicates that.

While many candidates are campaigning on issues such as free college education, student loan forgiveness or healthcare for all, each comes with a cost that could further expand the national debt level.

“Many people believe that a new infrastructure plan beyond the FAST Act could be in the cards for the next president. But unless they figure out a

and also pro-infrastructure. The election really is going to have a huge effect on which party gets into power and whether those types of things continue or not.”

Phillips remains confident though that an infrastructure plan is not off the table no matter who is in power.

“Our economy, our infrastructure, the roads that we travel on and move goods and services, that is a competitive advantage for us in this country, and it has deteriorated to a point where something needs to get done. When they

workforce are already trained for it.

“A lot of projects require [ACI certification] in their contract documents, so we're really trying to encourage people that are going to work in this industry, particularly at the workmen level, that they're qualified to do the work,” explains Poston. “That's really our biggest program in order to make sure we have a qualified workforce.”

DEBT LEVELS COULD IMPACT INFRASTRUCTURE FUNDING

nd3000/ iStock / Getty Images Plus

finally focus on some of the things that are important to the American public, I think that they'll get to infrastructure,” he concludes.

RESILIENT BUILDINGS OFFER FUTURE OPPORTUNITIES Climate change—and the extreme weather events that are increasing as a result—have spurred a new debate in regards to constructing homes and buildings with concrete versus wood.

While we have been buildings homes with light-frame wood construction since the 1950s, a need for more resilient construction is growing.

“While each region of the U.S. faces a unique combination of weather hazards, every state in the country has been impacted by at least one billiondollar disaster event since 1980," says Adam Smith, an applied climatologist with the National Oceanic and Atmospheric Administration (NOAA) in Ashville, N.C., who tracks extreme weather events that cause more than $1 billion in damage.

"Over the last four decades (19802019), the U.S. has sustained 250 separate weather and climate disasters where overall damages/costs exceeded $1 billion (including Consumer Price Index adjustment to 2019). The total cost of these 250 events exceeds $1.7 trillion,” he adds.

The concrete industry has a huge opportunity to not only offer a solution to this devastation with more resilient homes and buildings, but also to save lives.

T h o A

SUSTAINABILITY GAINS TRACTION The demand for a green environment and sustainability will continue to evolve this year within the industry.

The cement industry, which is major component in concrete, unfortunately seems to get a black eye in terms of sustainability—something Poston says is “probably unjustifiable in some ways.”

“It certainly takes a lot of energy to produce cement, but when you look at the

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STATE OF THE INDUSTRY other side of the equation and look at resiliency of concrete and its durability, you get much longer life out of a concrete structure,” he notes.

Phillips agrees, adding that “correcting the false narrative” is at the top of the NRMCA’s to-do list in 2020.

“We have a tremendous story to tell from a concrete perspective on the contributions we've made to society, to human health, to life safety to resilient communities, and that's all wrapped in being able to tell a very truthful and fact-based narrative about the impacts of concrete in these carbon discussions that we're having,” he says.

Combined the cement and concrete industries are the second largest industrial emitters of CO2 on the planet, accounting for about 8% of global CO2 emissions. Phillips suggests, however, that concrete’s natural ability to absorb atmospheric carbon will allow the industry over time to be part of a climate change solution.

A 2016 paper in Nature Geoscience supports this claim, suggesting that the world's concrete has been absorbing about 43% of those original emissions.

The article says there may be some ways to speed up or strengthen this absorption process, which is an area scientists are still working on.

In the meantime, the NRMCA is working on engaging producers throughout the industry to take an interest in the topic.

“This is an issue that needs full engagement from our members and other producers,” Phillips adds.

And while blaming the world’s environmental woes on the concrete industry is far from fair, there will continue to be interest in alternative options for sustainable building.

“It’s not coming from all directions, but I can feel an upsurge and the need for that,” Poston says, pointing specifically to long-term investors or property owners and public agencies.

In preparing for that upsurge, ACI updated its most recent building code from ACI 318 19 to include provisions that allow for recycled aggregates and alternative cements that don’t have as much portland cement. It is the firsttime using alternatives has been codified.

“We’ve given the nod to those that are acceptable, but they have to demonstrate certain performance requirements before they are utilized on a project,” Poston notes.

TECHNOLOGY KEEPS ADVANCING The use of technology to make life easier, more efficient and profitable for the contractor will continue to trend.

ACI, for example, has plans to rollout an interactive building code called 318 Plus that will make it easier to keep up with ever-changing codes.

“There’s this feeling from designers that we're getting more and more codes and they're changing all the time. How do we keep up with all this,” Poston says.

In addition to a reorganization of the codes, this program will allow you to look at diagrams in 3D. “Everybody thinks that, unfortunately, the concrete industry doesn't adapt that well to those sorts of things,” Poston notes. “But now more than ever, when you walk out on a jobsite, the contractor, their supervisors and foreman all have tablets, and information is being sent over from the office directly to them in the field.

“It’s much more real time kind of access to things on a project,” he adds.

Poston also points to a growing trend in modularization, where large portions of a structure are build offsite and then brought in to be installed.

Currently, modular construction accounts for only 5% of all commercial construction in the U.S., according to the Modular Building Institute, but it is growing. McKinsey & Co. estimates market value for modular in new real estate construction could reach $130 billion in Europe and the U.S. in the next decade.

AGING ECONOMY VULNERABLE TO GLOBAL RISK For 2020 at least, all signs point to a positive year. It is important to note, however, that the economy has reached its peak and may be more susceptible to risks from global economic activity and political instability.

“It's important to recognize that when we say this economy is getting older, that it's lost some its zip, that the growth rates will ease a little bit, what we're also saying is that increasingly, as the economy ages, it becomes more vulnerable to shocks,” Sullivan notes.

He points to Brexit, for example, which could cause a slow down of the global economy that could have an adverse impact on the construction industry. There are also unknowns in the Middle East and a threat of ware that could have an unknown impact.

“The most important way in which these external events could impact us is by hitting the consumer psyche or consumer sentiment,” Sullivan adds, explaining that if the consumer is less confident in the economy, they typically keep their money in their pocket.

But, the fundamentals Sullivan sees in place right now suggest a continuation of the last several years, including modest economic growth, modest construction spending growth and modest demand consumption growth.

Poston further adds that while we are all aware that this long period of expansion will come to end at some point, it doesn't look like it's going to happen this year.

“Things could change in a minute, but it's a positive sign when you look at the number of projects that are in the development stage and in the design stage,” he adds. “There’s going to be a lot of construction starting on those projects this year as well as things coming to completion. As I travel around the country, there’s no doubt that whatever state you're in the new state bird is the construction crane.”

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DECORATIVE CONCRETE

By Amy Wunderlin

Stamped Concrete Replicates

WHITE LIMESTO

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To achieve the homeowner’s vision of white cement, the contractor experimented with layering an ash white color hardner with an ash white antiquing release.

Photo Credit: Rich Grimes of Grimes Aquatech Pools and Spa

TONE

Indiana contractor Mike Lindsey uses a white-on-white stamping technique to achieve a limestone look.

on just any project. He sets his sights on jobs that no one else can do.

“There are a lot of people that do stampings and I like to do something that no one else can do or will do. I just like the challenge of it,” he says.

In 2017, Lindsey was challenged with replicating a homeowner’s vision for a white limestone pool perimeter with matching walkways.

ike Lindsey has more than once been called a workaholic. Its safe to assume many concrete contractors would likewise fall into that category.

But after almost 50 years in the business, Lindsey is not willing to take

WHY NOT WHITE CEMENT?

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Long distances and hot temperatures prevented Lindsey from using white cement to replicate the limestone look on this project. In hot weather, white cement sets up quicker and can be very difficult to work with.

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DECORATIVE CONCRETE

The project took five to six weeks to complete because the concrete contractor had to work around the pool contractor’s schedule.

Photo Credit: Rich Grimes of Grimes Aquatech Pools and Spa

“The homeowners were looking for something white, but due to the temperatures we were dealing with in the middle of summer, white cement wasn’t really an option,” Lindsey explains.

To fulfill the homeowner’s vision, Lindsey experimented with layering an

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ash white color hardner with an ash white antiquing release.

“Even though they are the same color, there is just a hint of difference, which made a modeling in the concrete and gave it the limestone look when we texture skinned it,” Lindsey says.

Lindsey used Scofield’s Lithochrome Color Hardener in ash white, stamping with Lithotex Pavecrafters Fractured Slate Embossing Skin. This irregularshaped, seamless tool is what creates a surface texture that looks like natural stone. He finished with Scofield’s Lithochrome Antiquing Release also in ash white, which makes separating the stamping tools from the freshly placed concrete easier.

The travel from the cement plant to the jobsite was also a significant challenge. Because the distance was so great, Lindsey’s crew added chemical reducers to the concrete to slow the setting rate. The concrete also all had to be pumped from pump trucks.

And while Lindsey did not use white cement, the concrete on this project did set a little bit slower than normal.

The key, he says, is being able to control your volume. “Try not to exceed your limitations with your help,” he adds.

THE RIGHT MAN FOR THE JOB The project took about five to six weeks to complete because Lindsey and his crew had to work around the pool

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While the bright, clean lines of Lindsey’s white-on-white walkways clearly shine, the shotcrete pool is still the centerpiece of the project.

Designed by Grimes himself, his crew first had to remove an old pool and dig 8 feet down to reach undisturbed earth.

“I started with an 8-inch slab. I think it was like 22 by 46 or something to that effect on the bottom when I got to undisturbed earth. And then the pool was actually set on 2-foot sonotubes every 4 feet on center off of that slab,” Grimes explains.

To support the weight of the pool, the slab consisted of a rich mix of fiber mesh and steel. “Obviously a concrete pool with water in it can’t move,” Grimes adds.

The design also featured 3-foot by 3-foot squares around the perimeter of the pool. In order to keep them from moving, each one of the squares was poured on 18-inch sonotube, roughly 3-feet deep into the ground.

Artificial turf was also tied into the pieces. “If those 3 by 3 pieces weren’t kept exactly perfect, the turf that we tied them to would have ripped or wrinkled,” explains Grimes.

The use of individual sonotube for the entire pool deck, Grimes says, sets this installation apart from other jobs he has completed.

“We used 6-inch pylons every 6 feet on center for the rest of the deck, which we do frequently here because we’re never on level ground; Indiana’s always on a slope. You’ve got three different systems there that are holding this basically 8 feet above the original, so what really made that project unique is the fact that there was so much structure that held that in place,” Grimes concludes.

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DECORATIVE CONCRETE

The 3-foot by 3-foot squares were poured on 18-inch sonotube, roughly 3-feet deep, to keep them from moving.

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contractor. While Lindsey completed all the decorative work, the pool was installed by Grimes Aquatech Pools and Spa of Bloomington, Ind. “We were assisted by the pool company, and they went out of their way to make everything right for us,” Lindsey notes.

Lindsey has been the pool company’s finisher for several years.

“The homeowner wanted to do something white and then instead of going with just white concrete, Mike came up with this white on white, and it turned out beautiful,” says Rich Grimes, president and owner of Grimes Aquatech Pools and Spa. In fact, since then, Grimes says they’ve done several pool perimeters using the technique.

“We had done a lot of whites in the past, but it always had more greys in it.

When we presented the design to the homeowner, the customer specifically wanted whiter. Mike said, ‘Well, I’ve never done this, but we could try white on white and do a sample for her.’ And that’s how it came about,” Grimes adds.

Lindsey’s willingness to try something new makes him an

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Once the concrete contractor’s job is complete, the pool contractor is responsible for the finishing touches.

Photo Credit: Rich Grimes of Grimes Aquatech Pools and Spa

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Scofield’s Lithotex Pavecrafters Fractured Slate Embossing Skin created a surface texture that looks like natural stone.

invaluable asset to Grimes business.

Grimes initially hired him for a pool installation at Indiana University, which is where Lindsey is employed during the day.

“Since then, the reason I continue to hire him is because he's very particular about everything,” Grimes says. “We’re expected to create something special, and I'm only as good as who I hire.

This is something that if you don't do it every day, you're never going to be the best. He is the piece that gives us the ability to create projects that I don't have to go back and fix.”

Lindsey’s well-trained crew is another reason.

“The problem with stamping is it’s so labor intensive that you can't get a consistent job unless you have adequate people that are trained,” Grimes explains, adding that Lindsey’s crew is like a welloiled machine. “They all know what they're doing, and they all have a position on that crew that works.”

And while Grimes does all of the structural prep work, he knows that the work of the finisher is essential.

“What I do doesn't show, but what he does is the most important thing. If I don't hire the person who can do that quality, then I can't produce the kind of work that we're expected to do. He’s very valuable,” Grimes adds.

Photo Credit: Rich Grimes of Grimes Aquatech Pools and Spa

Artificial turf ties the 3-foot by 3-foot concrete squares together.

Photo Credit: Rich Grimes of Grimes Aquatech Pools and Spa

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CONCRETE TESTING

By Wendy Henry

CONCRETE FIELD TESTING

101 Using appropriate methods and procedures to correctly field test concrete products can prevent costly project delays.

A

shortage of skilled labor continues to be the dominate issue in the construction industry, and rightfully so. However, delays in construction schedules have always been a thorn in the side of contractors, and history shows that probably won’t change.

The success of any construction project—single family home, school, hospital, stadium, restaurant—is predicated on preventing problems that cause costly delays. While there are many factors that can disrupt a schedule, few are more detrimental than problems with the quality of concrete on a job. Best case scenario, the project will be temporarily Conducting a slump test following ASTM C143 is one of the first steps in field testing the compressive strength of concrete.

Photo Credit: Quikrete Companies

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halted until test results are validated.

Worst case scenario, the original work will be removed and redone. Either way, bad news for project efficiency, quality and profitability.

“Nothing is more frustrating than starting construction on a new home and almost immediately being forced to stop because some building material can’t meet spec,” says Ben Morris, owner of Atlanta-based custom builder/developer Paramount Reality Group. “Unlike siding, roofing or some other product used later on the project, concrete is literally and figuratively the foundation to any successful build. Nothing else can happen until that concrete is right on a job, so we count on manufacturers to live up to their performance claims.

Otherwise, we lose time and money get the project back on track.”

Fortunately, unlike unpredictable weather, project delays can be avoided by correctly field testing concrete products using appropriate methods and procedures. The process is grounded in following standardized test methods defined by the American Society for Testing and Materials (ASTM), the American Concrete Institute (ACI), the American Association of State Highway and Transportation Officials

Cylindrical concrete specimens being field tested should be made consistently to avoid false low compressive strength results.

areas of field testing to understand and track.

Photo Credit: Quikrete Companies

SLUMP MEASUREMENT

(AASHTO), or another organization approved for the specific project at hand. The field testing should also be conducted by a ACI concrete field testing technician or comparable professional certified to collect, test and analyze concrete samples from a jobsite according to ASTM C 31 (Standard Practice for Making and Curing Concrete Test Specimens in the Field) and ASTM C 39 (Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens) or other validated methods.

Whether it’s the foundation for a 10-story building, footings on the deck of a custom home or the industrial floor of a warehouse, field testing the concrete to make sure it meets required compressive strength is critical. For this reason, manufacturers diligently conduct quality control compressive strength tests before their concrete enters the market. However, field testing by a certified third-party organization should take place on every job.

Furthermore, contractors should clearly understand the process and be engaged with the field-testing organization to make sure results are accurate. It also allows a contractor to quickly and effectively react to field tests that suggest compressive strengths fall short of project specifications.

The following are several important

It may seem odd, but field testing the compressive strength of concrete starts long before it sets or cures on the jobsite. Measuring the consistency of the concrete, or slump, following ASTM C 143 to confirm it’s within the specified range is the first step in field testing.

While ready mix concrete producers simply report the slump prior to delivery, for packaged concrete manufacturers, it’s important that the quantity of water added in the field is both documented and confirmed to produce a slump within the manufacturer’s specified range for that concrete.

A standard pre-packaged concrete typically specifies a slump of 2 to 3 inches, while there are other concretes designed to be used at a higher slump, such as 3 to 5 inches to meet or exceed specific project requirements. The more water that is added to a given concrete, the higher the slump it will have. The higher the slump for a given concrete, the lower the strengths, so it is critical to stay within the specified slump range.

CURING CONDITIONS Understanding the jobsite environment also plays an important role in field testing the compressive strength of concrete specimens. If a concrete specimen freezes within the first 24 hours after being molded, or before it has reached a minimum strength

The number of cylindrical concrete specimens cast for each test age is determined by the project requirements, but should be no fewer than two.

Photo Credit: Quikrete Companies

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CONCRETE TESTING

of approximately 500 PSI, it will lose significant overall strength. Because of this, concrete specimens should be stored for up to 48 hours in a moist environment having a temperature of 60 °F to 80 °F (16 °C to 27 °C).

In addition, concrete specimens should not be exposed to direct sunlight or radiant heating, as these conditions would cause the concrete specimens to lose some of the water needed to react with the cement for strength gain.

After completion of initial curing, but within 30 minutes of specimens being demolded, the environment in which the specimens are stored must be even more tightly controlled, with a temperature of 70 °F to 77 °F (21 °C to 25 °C). There must be free water on the specimens at all times, which can be achieved through use of water storage tanks or moist rooms. By closely managing these conditions during the entire remaining curing process, the field created samples should accurately reflect the compressive strength of the concrete.

SPECIMEN PREPARATION It may be surprising how many factors can impact the quality of the cylindrical concrete specimens, which ultimately are used to determine the compressive strength. Poorly made specimens may produce false low compressive strength results. The number of concrete cylinders to be cast for each test age is typically dictated by the project requirements. If the number is not specified, no fewer than two, and preferably three, are generally recommended for each test age. A single specimen will not provide sufficient data to indicate if that specimen was faulty.

The specimens must be cast on a flat and level surface that is not exposed to any movement due to nearby forklift, crane or other vehicular traffic, or even nearby concrete mixers in operation.

The method used to place the concrete into the cylindrical molds (of size as directed by project requirements) is also critical. The concrete must be added in multiple layers, with the exact

The typical slump range of prepackaged concrete is 2 to 3 inches, but it can be higher or lower to meet project specifications.

Photo Credit: Quikrete Companies

when curing concrete slabs or by using other means. Loss of moisture will result in lower compressive strength results of the specimens.

BREAK TESTING

number of layers depending upon the size of the aggregate. Each layer must be of approximately equal depth and consolidated, typically by rodding and tapping the outside of the mold. Not following the consolidation requirements as defined in ASTM C 31 can leave air voids, which will produce false low compressive strength results. Similar to finishing a slab, the concrete at the surface of the cylindrical molds should not be overworked. The finished surface should be a flat and even with no pits or bumps greater than 1/8 inch. If not, it will result in uneven contact with the platens of the compressive strength machine, which again, may result in false low compressive strength results.

TRANSPORTATION As we all know, damage can occur during the transportation of anything from one place to another. Concrete specimens are no different. Specimens should never be transported until at least 8 hours after the concrete has achieved final set. Final set is when the concrete has completely lost its plasticity and has hardened. If the concrete specimens are moved sooner than eight hours after final set, they may be damaged, causing false low compressive strength results.

During transportation, moisture loss must be prevented by covering with plastic or wet burlap like that used

With proper slump, curing conditions, specimen preparation and transportation verified, the final and ultimate test begins. Each secured concrete cylinder should undergo a break test at the manufacturer’s laboratory or other approved third-party facility. The equipment should always be properly calibrated. The load should be maintained at a rate of 27 to 42 psi/second. Testing should be continued until the sample fails and presents a well-defined fracture.

The strength of the concrete is determined by dividing the maximum load by the area of the cylinder’s end.

Calculate the average of all specimens from the same test age then round to the nearest 10 psi. If measured strength is lower than expected, examine the specimens to see if they are manifestly faulty, for example, if they contain large air voids indicating that they were not properly compacted. Results of any such specimens should be discarded.

When the standard procedures for field testing are followed correctly, contractors can count on concrete that will keep projects on schedule.

“An early problem with concrete quality that adds two weeks to a project schedule can quickly escalate into two months dealing with building code officials and rework,” adds Morris, a 20-year industry veteran. “We avoid that situation by conducting field tests regularly on all jobs.”

Wendy Henry has been the quality assurance manager for The QUIKRETE Companies for 16 years. She gained her initial experience with cementitious products as a quality control manager for Custom Building Products, which has since become a QUIKRETE Company.

32 Concrete Contractor | February/March 2020 | www.forconstructionpros.com/concrete

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CONCRETE TECHNOLOGY

By Damon Thomas

Riding the Automation

WAVE

Materials testing is still heavily reliant on humans, but cloud-based platforms that communicate directly with break machines are taking us into the future.

F

or nearly 150 years, construction materials testing has been a manual effort. Whether in an engineering lab, a commercial lab, at a cement/ready-mix manufacturers’ sites or in the field, specimens are labeled with markers or chalk. Load settings are controlled with a hand valve. Results are recorded and transferred manually. Details are noted,

but sparsely, and put in a folder, in a cabinet—somewhere.

In short, materials testing is heavily reliant on humans. Just like it was 150 years ago.

It won’t come as a surprise to readers that the construction industry is years behind the rest of the automated world.

In fact, according to McKinsey Global Institute’s (MGI) Digitization Index, "Construction is among the least digitized sectors in the world. In the United States, construction comes second to last, and in Europe, it is in last position on the index."

That is all changing.

“Ten years ago, nearly all materials testing machines sold in the United States were manual. Now, more than 70% of newly purchased machines are automatic,” says Forney LP CEO Jeff Dziki. “In a few more years, manual machines will be gone, and all machines will be automated. The performance difference is just that compelling.”

Dziki is one of the parties responsible

for what we see as a paradigm shift in materials testing. In 2018, the firm released ForneyVault, a cloud-based construction materials testing platform that communicates directly with Forney break machines. As the first machine-tomachine communication tool for materials testing, the platform can deliver approved break test results to a client within minutes. Results can be viewed from any internet-enabled device.

As the president of CTL|Thompson Materials Engineers, Inc., I oversee one of the busiest materials testing labs in the U.S. In October 2018, we launched ForneyVault after integrating the platform with our existing Forney break machines and MetaField, our materials testing software package, designed by Agile Frameworks.

As we complete our first year of use, we are recognizing great benefits to our lab. Our clients, including developers, contractors and manufacturers, receive test results faster, which delivers the benefit of

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Machine learning opens the door of opportunity for producers who can use the technology to analyze mix design yields and create more optimal mixes.

Photo Credit: ForneyVault

increased productivity. We also believe the industry will benefit from the actionable insights that result from a national warehouse of materials testing data.

Will it help us ride the wave of digitization into the future? I believe so.

Here’s why.

AUTOMATION BREEDS INNOVATION

Our lab is among the busiest in the country. Our lab technicians routinely arrive at 5 a.m. to accommodate the large testing load. Some days we have 300 cylinders on the schedule, which can take up to 16 hours to test. Through automation, we shorten the overall testing time and, more importantly, the results are recorded automatically into our ERP. They are then transmitted directly to the reviewing project manager and ultimately to the client, who can view them from any web-enabled device.

This data-delivery speed is a big change from the past, when it could take up to two days to review and deliver results.

In the case of another Forney client, whose volume exceeds our lab’s, the results were even more dramatic. That lab breaks up to 600 cylinders per day during its busiest months. In the past, it took three manual machines operated by three people to produce 35 cylinder tests per hour. Since automating the process, they are running five automatic machines with one technician and testing 100 specimens per hour.

Detractors might suggest that automation is costing the industry critical jobs. We see it differently. As one of the most sophisticated testing labs in the country, we invest heavily in the initial and ongoing training of our technicians. Automation gives these highly trained professionals more time to focus their expertise on efforts that can support innovation in the lab and provide additional insights to our clients.

The speed and reliability of the system also can boost productivity in the

field. If a construction team knows, with absolute certainty, when a test result will be delivered, they can better deploy their own resources — both human and machine.

AUTOMATION IMPROVES ACCURACY Not only was manual testing tedious and time-consuming, but it was also vulnerable to human error. In the past, we recorded break machine data manually and then entered it manually into our database. We consistently had three opportunities for error: (1) during data recording, (2) while writing reports by hand and (3) when entering data into the database. Our technicians are highly trained and professional, but even a nearly perfect tech can tire after 16 hours of testing and writing 200300 test reports.

With automated testing, human hands only intervene at three touchpoints: (1) preparing the specimen, (2) determining the specimen parameters for testing and (3) physically loading the specimen into the machine. The rest of the testing runs seamlessly— and flawlessly.

Even manual data entry is monitored to avoid inaccuracies.

Sample or specimen parameters live in a cloud database and are tied to a unique identification number. When a technician selects the specimen to load from the machine display, it shows all previously defined information, including its age and required strength.

Because of this, the machine can flag a specimen and alert the technician to potential problems. If parameters of the specimen are outside the normal range, or we attempt to run a test outside of the scheduled day, the machine recognizes the problem and sends a warning signal. If the specimen is impossible to test due to capacity or inaccurate recording, the “start test” button is disabled.

Because each specimen has a unique ID, the original results are archived in our database and searchable. This last point may have the greatest impact on the industry as a whole.

AUTOMATION LEADS TO DIGITIZATION

A 2019 report from BST Global, titled “The State of the AEC Project Lifecycle,” noted: “the architectural, engineering and construction sector remains woefully inefficient when it comes to dealing with the mounds of data stakeholders are accumulating in all phases of their operations.”

Data has become the most valuable currency of our time. Nearly 98% of executives from Fortune 1000 companies will invest in big data and AI this year, and “the ability to make sense of the data avalanche,” according to Forbes contributor Michelle Evans, “will be what distinguishes the winners from the losers in the next decade.”

Yet, as MGI noted, construction remains among the least digitized industries in the U.S. Advances like the ForneyVault serve labs like ours, but I am hopeful they will start an “avalanche” of digital adoption in the industry.

One of the reasons construction has been slow to digitize is the “one-off ” nature of our industry. Even for a large developer, each construction project has its own discrete properties. Within a project, each specimen is unique.

ForneyVault’s searchable database allows labs and producers the ability to analyze the data holistically and identify trends, issues or possibilities.

For example, using machine learning, producers could analyze mix design yields and design more optimal mixes. As the data warehouse grows, so will the opportunities for actionable insights.

“This new technology will help transform the construction industry,” said Dziki. “Truly automated testing is now the new standard in construction materials testing, and labs that don’t automate will soon be replaced by ones that do. You can swim against the tide, but it will eventually pull you along.”

1065477622 / iStock / Getty Images Plus

Damon Thomas, P.E., is an architectural and civil engineer with nearly 30 years experience in construction materials testing and subsidence engineering. He is president of CTL|Thompson Materials Engineers, Inc.

www.forconstructionpros.com/concrete | February/March 2020 | Concrete Contractor 35

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SPECIFICATION GUIDE: POWER TROWEL

Power Trowels

A compilation of technical information when choosing your next power trowel.

1. ALLEN HDX600 HYRDRA-DRIVE EXTREME RIDING TROWEL The HDX600 was designed with the high volume flatwork concrete contractor in mind.

This riding trowel comes with dedicated panning/finishing modes, digital readouts for accurate fuel levels and diagnostics, and a large 13-gal. fuel tank for longer run times. It is also equipped with powerful pumps that help maintain excellent torque even at high rotor speeds. This makes the machine excellent for panning or finishing operations.

ForConstructionPros.com/21113036

Model

Walk Behind or Ride-On

Weight (lbs)

Troweling Diameter

Rotor RPM

# of Blades

Steering: Mechanical/Hydraulic

Handle Options (Walk Behind Only)

Engine HP

Fuel Type

HDX600

Ride-On

N/A

46”

165

5 bladed spider

Hydraulic

N/A

50

Diesel

2. WAGMAN METAL PRODUCTS GHP LP230 POWER TROWEL The propane powered GHP LP230 is a highly maneuverable ride-on machine that will easily fit through a 32 in. doorway while processing the concrete without concern for high voltage cables. With a path of 30 in. by 61 in., the GHP LP230 will easily fit into the bed of a pickup truck. The standard wheel lift kit makes it easy to change diamond pads without requiring a forklift.

ForConstructionPros.com/20992254

Model

Walk Behind or Ride-On

Weight (lbs)

Troweling Diameter

Rotor RPM

# of Blades

Steering: Mechanical/Hydraulic

Handle Options (Walk Behind Only)

Engine HP

Fuel Type

LP230

Ride-on

640 lbs.

Twin 30”

130

8

Mechanical

N/A

11.7

Propane

3. HOVERTROWEL PNEUMATIC WALK BEHIND MODELS Weighing less than 45 lbs., the HoverTrowel is a patented power trowel designed for finishing polymer toppings. Interchangeable high and low pneumatic motors make it ideal for most of today’s polymer toppings. A six-position telescoping handle, coupled with interchangeable guards creating 25” and 34” trowel paths make this trowel easy to maneuver in confined spaces and wide open areas. A HoverTrowel can be used for most epoxy, cementitious urethane, polymer modified, EPDM rubber and many other hybrid toppings with a variety of blades and floats. Its design makes these pneumatic motors easily interchangeable with the company’s four-cycle engine as well.

ForConstructionPros.com/12039894 Model

Walk Behind or Ride-On

Weight (lbs)

Troweling Diameter

Rotor RPM

# of Blades

Steering: Mechanical/Hydraulic

Handle Options (Walk Behind Only)

Engine HP

Fuel Type

High Torque Air

Walk Behind

42 lbs.

25” or 34”

0-60

3

Mechanical

Telescoping

I-R .76 hp

Pneumatic

Model

Walk Behind or Ride-On

Weight (lbs)

Troweling Diameter

Rotor RPM

# of Blades

Steering: Mechanical/Hydraulic

Handle Options (Walk Behind Only)

Engine HP

Fuel Type

Low Torque Air

Walk Behind

38 lbs.

25” or 34”

0-60

3

Mechanical

Telescoping

I-R .41 hp

Pneumatic

36 Concrete Contractor | February/March 2020 | www.forconstructionpros.com/concrete

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EXPERIENCE A CONCRETE DIFFERENCE WITH THE CUMMINS X12.

The lightest in its class, the new Cummins X12™ engine is revolutionizing the concrete industry. The X12 doesn’t just set new performance standards of medium-bore engines – it sets new performance standards for your business.

Tipping the scale at just 2,050 pounds, the productivity champion leads the industry in power-to-weight with up to 500 hp and 1700 lb-ft of peak torque.

Backed by the largest support network, the X12 delivers power and a bigger payload to keep you moving forward in a world that’s Always On. Move your business forward at www.cumminsengines.com.

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SPECIFICATION GUIDE: POWER TROWEL

4. EDCO T364 WALK-BEHIND TROWEL The model T364 is a 5.5 hp gasoline unit with an optional Leveling System for smooth troweling.

It has a 36-in. troweling diameter, standard Lifting Bail and features bolt-on blades.

ForConstructionPros.com/12039874 Model

Walk Behind or Ride-On

Weight (lbs)

Troweling Diameter

Rotor RPM

# of Blades

Steering: Mechanical/Hydraulic

Handle Options (Walk Behind Only)

Engine HP

Fuel Type

T364

Walk-Behind

186 lbs.

36”

118

4

N/A

1

5.5

Gas

Model

Walk Behind or Ride-On

Weight (lbs)

Troweling Diameter

Rotor RPM

# of Blades

Steering: Mechanical/Hydraulic

Handle Options (Walk Behind Only)

Engine HP

Fuel Type

T-364-3

Walk-Behind

192 lbs.

36”

115

4

N/A

1

3

Electric/230 V

5. MBW F36 WALK-BEHIND POWER TROWELS MBW understands to function properly, power trowels must maintain a precise perpendicular relationship between the gearbox’s output shaft and blade arms. They have gone to great lengths to maintain this critical relationship. MBW’s F36 walk-behind power trowel feature the industry’s heaviest bearings, output shafts, gears, spiders and blade arms. Comparison of these critical components to those of any competitor answers the question as to why MBW trowels run so well for so long.

ForConstructionPros.com/20858037

Model

Walk Behind or Ride-On

Weight (lbs)

Troweling Diameter

Rotor RPM

# of Blades

Steering: Mechanical/Hydraulic

Handle Options (Walk Behind Only)

Engine HP

Fuel Type

F36

Walk-Behind

183 lbs.

38”

70-135

4

Mechanical

Standard, EZ Pitch, Low Vibe

Honda GX160, 5.5 hp

Gas

Model

Walk Behind or Ride-On

Weight (lbs)

Troweling Diameter

Rotor RPM

# of Blades

Steering: Mechanical/Hydraulic

Handle Options (Walk Behind Only)

Engine HP

Fuel Type

MK8-91

Ride-On

746 lbs.

76”

0-125

8

Hydraulic

N/A

23.5

Gas

6. HUSQVARNA BG 244 WALK-BEHIND EDGER TROWEL The Husqvarna BG 244 is a gas-powered, walk-behind edger trowel, designed to deliver a smooth, durable concrete surface, specially developed for use in confined spaces and corners.

It offers the QUICKSTOP clutch for safety. The BG 244 comes equipped with a foldable, de-vibrated and height adjustable handle and a maintenance stand for increased uptime.

ForConstructionPros.com/21046667

Model

Walk Behind or Ride-On

Weight (lbs)

Troweling Diameter

Rotor RPM

# of Blades

Steering: Mechanical/Hydraulic

Handle Options (Walk Behind Only)

Engine HP

Fuel Type

Husqvarna BG 244

Walk-Behind

132 lbs.

23.6”

40-115

4

N/A

Foldable/Adjustable/De-vibrated

3.5

Gas

Model

Walk Behind or Ride-On

Weight (lbs)

Troweling Diameter

Rotor RPM

# of Blades

Steering: Mechanical/Hydraulic

Handle Options (Walk Behind Only)

Engine HP

Fuel Type

Husqvarna BG 375

Walk-Behind

192 lbs.

35.4”

40-115

4

N/A

Foldable/Adjustable/De-vibrated

4.8

Gas

Model

Walk Behind or Ride-On

Weight (lbs)

Troweling Diameter

Rotor RPM

# of Blades

Steering: Mechanical/Hydraulic

Handle Options (Walk Behind Only)

Engine HP

Fuel Type

Husqvarna BG 479

Walk-Behind

227 lbs.

44.9”

40-115

4

N/A

Foldable/Adjustable/De-vibrated

8.4

Gas

38 Concrete Contractor | February/March 2020 | www.forconstructionpros.com/concrete

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SPECIFICATION GUIDE: POWER TROWEL

7. MULTIQUIP HYDROSTATIC 6-FOOT RIDE-ON POWER TROWEL The new MQ Whiteman LD6 is the only fully hydrostatic 6-ft. ride-on trowel on the market today. Incorporating a proportional servo controlled pump and high torque drive motors, the LD6 can achieve performance levels unmatched in the industry by any 6-ft. ride-on trowel.

Proportional hydraulic steering enhances maneuverability, while the all new walk-around frame design simplifies maintenance and offers easy access to all serviceable components.

ForConstructionPros.com/21112985 Model

Walk Behind or Ride-On

Weight (lbs)

Troweling Diameter

Rotor RPM

# of Blades

Steering: Mechanical/Hydraulic

Handle Options (Walk Behind Only)

Engine HP

Fuel Type

LD6

Ride-On

865 lbs.

75”

0-140

8

Hydraulic

N/A

4.8

Gas

8. WACKER NEUSON CRT 48-PS SERIES Concrete contractors can choose between two gasoline engine options on Wacker Neuson’s 48-in. power steer (CRT 48-PS series) ride-on trowel product line. A new model, CRT 48-57K-PS, is powered by a 57-hp liquid cooled Kubota gasoline engine. It joins the 35-hp Vanguard air-cooled engine powered model, the CRT 48-35V-PS. The two models offer concrete contractors the ability to choose the power source that best fits their needs plus get all the benefits of Wacker Neuson’s patented two mode steering system and other high performance features.

ForConstructionPros.com/12040035 Model

Walk Behind or Ride-On

Weight (lbs)

Troweling Diameter

Rotor RPM

# of Blades

Steering: Mechanical/Hydraulic

Handle Options (Walk Behind Only)

Engine HP

Fuel Type

CRT 48-57K-PS

Ride-On

1,500 lbs.

48”

25-165

10

Power Steer

N/A

57

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

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40 Concrete Contractor | February/March 2020 | www.forconstructionpros.com/concrete

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9. TORO PT-36PP POWER TROWEL Toro power trowels feature contoured adjustable handles and a rotating stabilizing ring for precise handling that will deliver a smooth concrete finish. There are four models to choose from and each comes equipped with a Honda engine. The Toro Dyna-Clutch safety feature is incorporated into each unit and will stop the blade without shutting down the engine. The PT-36PP features Toro’s patented Pro-Pitch blade adjustment system that provides smooth, quick pitch changes to ensure blades are at the optimal angle for a perfect finish.

ForConstructionPros.com/10879819 Model

Walk Behind or Ride-On

Weight (lbs)

Troweling Diameter

Rotor RPM

# of Blades

Steering: Mechanical/Hydraulic

Handle Options (Walk Behind Only)

Engine HP

Fuel Type

PT-36 PP

Walk-Behind

219 lbs.

36”

50-130

4

Mechanical

Adjustable

4.8

Gas

10. LAVINA LP36 POWER TROWL

er oled he et all

The Lavina LP36 is an all-new ride-on power trowel from Superabrasive. Integrated wheel set lifts the trowel (200mm) for changing blades and tools quickly and easily. One person can raise and lower the integrated wheel, using a jack at the rear of the machine. A powerful Kawasaki FX1000V engine with Lavina Fuel Minder offers closed loop fuel management and optimal performance. In addition, continuously variable transmission provides superior performance by continually adjusting the drive ratio to obtain optimum torque and speed during all phases of finishing from low speed high torque to high speed burnishing.

ForConstructionPros.com/21113442 Model

Walk Behind or Ride-On

Weight (lbs)

Troweling Diameter

Rotor RPM

# of Blades

Steering: Mechanical/Hydraulic

Handle Options (Walk Behind Only)

Engine HP

Fuel Type

LP36

Ride-On

1,389 lbs.

N/A

0-185

4

N/A

N/A

35

Propane

TP44-TD Asphalt Paver

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Hydraulic end-gates move in & out Two 9” independently operated cast augers Extra large cut off door Hydraulic tilt hopper All controls on the rear of the machine Tracks are fixed at 38” to accommodate screed style Screed extensions & loading doors are optional * Extra large drive motors for years of service! * Designed with service & maintenance in mind * Clean, simple, basic design * 0-6’ standard paving width * Video of the TP44-TD is available on salsco.com

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”Under Guard Rail Curber”

TPC-72 Guidance Control Concrete Paver

13HP Honda Engine Concrete or Asphalt Will accept all standard molds Special order molds available Extra large hopper Cast Auger

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TPC-72, 72” Screed (other screed sizes available) Hatz 74HP, Tier 4 engine 1.5 Cu.Yd. capacity hopper Variable speed adjustable vibrators Self-adjusting floating wings Adjustable string line sensors Radio controlled belly pack Loading conveyor system Video of the TPC-72 is available on salsco.com

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www.forconstructionpros.com/concrete | February/March 2020 | Concrete Contractor 41

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Polished Concrete Meets Glass The Rockett Concrete Overlay offers the benefits of polished concrete with the look of terrazzo.

by Amy Wunderlin

T

he demand for polishable overlays continues to grow, but the market is not for everyone. Job owners are attracted to the look and performance the flooring systems offer, which compares to terrazzo but at a lower cost.

While cheaper than terrazzo, polishable overlays are still expensive, and there is little room for error. The equipment and products needed are expensive, not to mention the hefty labor costs. Installation requires highly skilled contractors qualified in installation of self-leveling or trowel-grade overlays, as well as expertise in polishing.

Bart Rockett, owner of Philadelphia Polished Concrete, recognized that challenge when developing his own overlay system, which uses 100% Top: Telecommunications company Comcast chose Rockett’s Concrete Overlay for its new engineering building in Newark, Delaware.

Bottom: After working on the formula for months, Rockett developed a mix made up of three different types of glass.

Photo Credit: Bart Rockett

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recycled post-consumer glass chips to achieve that much-desired terrazzo look. He plans to take the method national this year through the carpenters’ union, beginning with a pilot program in Philadelphia to teach other contractors how to utilize this method on their own projects.

This training program, he says, is essential to the success of the system. In his experience, most overlays fail not because of the product but because of how the flooring system was installed. The pilot program will provide a year of training that ensures that every installer is on the same page and performs the process the same way every time.

“The company’s we are working

Because the overlay is so hard, it repels traditional dye that is meant to penetrate concrete.

Instead, color can be added to floors by using different colored glass chips.

Photo Credit: Bart Rockett

COMCAST PROJECT

with understand that a lot of these overlays that fail are due to miseducating the installer. Having a grassroots installation team with skilled guys who are very thorough and have a regiment of training, that’s where you can succeed,” Rockett says.

At a third of cost of terrazzo, the telecommunications conglomerate Comcast took an interest in Rockett’s flooring system when designing its new engineering building in Newark, Delaware.

Completed in the spring of 2019, the nearly 10,000-square-foot job won the grand prize in the polished concrete category of Sika Schofield Decorative Concrete Awards.

“We’re around 30% less expensive than terrazzo and we’re faster

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because we’re not setting metal. So you’re getting the benefits of polished concrete—non slip and water scrub clean—faster and without the price,” Rockett says. “That makes a big difference, especially when you’re doing 5,000 feet and we’re $8 less. We just saved you $40,000, and we’re going to turn around and do it faster.”

But looks aren’t everything. The patent-pending overlay system also boasts a 20-year warranty. Something Rockett says no other system can claim.

The standard warranty for most overlays in the current market is about 2 to 3 years. For corporations and schools spending hundreds of thousands of dollars on a floor, the limited warranty is not worth the risk.

Rockett's installation of the overlay for Comcast won the grand prize in the polished concrete category of Sika Schofield Decorative Concrete Awards.

Photo Credit: Bart Rockett

“They’re not comfortable given a 3-year warranty and spending $300,000,” explains Rockett.

This was true when Comcast approached Rockett about developing the overlay system for their project.

“They wanted to feel comfortable with what they were because this overlay is a new technology,” Rockett notes.

Being the only system in the business with a 20-year warranty backed by adhesive manufacturer H.B. Fuller is one of the factors enabling Rockett to work with customers like Comcast. He has also done floors for retailers such as Burlington Coat Factory and Target.

Meticulous procedural steps that include a supervised maintenance program are also essential to guaranteeing the 20-year warranty.

“If you’re spending $300,000 on a floor, we’re going to set you up and ensure that you have the proper tools to clean this floor, or we’re

going to talk to your maintenance people at the facility to make sure you’re using the right pads and neutralizing floor cleaner.”

THE SECRET SAUCE Like a lot of projects, the Rockett Concrete Overlay system was created following an architect request.

“Norr International Architects wanted to know if we could mess around with some glass, so I spent two months in my garage every day figuring out rations of glass,” Rockett recalls.

After some trial and error, he developed the perfect mix with three different types of glass that could create a 6400 PSI floor with a 3/8 thickness.

“It’s not going look like pyrite. but the method can create an area that can be sparkling and modern or traditional per the customer’s request,” Rockett says.

But finding the right glass to concrete ratio wasn’t the hardest

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p o a e

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part. Rockett says it took hundreds of hours to figure out how to grind it and then blend the overlay from the edges to the middle.

“It’s not a conventional grind or how you even do a normal overlay because the glass is so hard,” Rockett says. But, he adds, that once you’ve figured it out, doing the same process consistently “is a piece of cake.”

Because the overlay is patent pending, Rockett kept many of the details of the process to himself, but he notes that it is not that different from a conventional polished floor.

“We basically came up with a formula for having consistent glass mixed around the floor, rather than a broadcast which doesn’t work for achieving evenness,” Rockett explains.

The decorative saw cuts are where Rockett’s process begins to differ, however. “It’s like mini concrete pours. Half-inch concrete pours

The polishable overlay also boasts a 20year warranty, something no other product on the market today can claim.

Photo Credit: Bart Rockett

with aggregate but on a smaller scale,” he says.

The benefit of keeping the squares small is that if there is a problem, just the one square can be repaired rather than an entire floor.

In a test, Rockett says he saw cut out a small square, poured a new one, and feathered it in without leaving a trace.

Finally, the system calls for a total densification.

But more than anything, Rockett reiterates how important having the proper team in place is to the installation of polishable overlays.

“Having a little execution team with a nice resume of consistent, great looking work is the basis of any successful business,” he says, adding, “It’s very labor intensive, and the necessary products are relatively expensive, but the floors are ultimately less costly than others in the market, achieve a luxury look and offer lifetime benefits that reduce expense in the long run.”

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5

By Jim Cuviello

A

brasives are the most important tool for mechanically processing concrete to a polished finish. They come in many forms, shapes and sizes and are made out of various materials whose bonding varies in hardness.

There are multiple variables and

W

things to Consider When Selecting an Abrasive conditions that need to be considered when choosing your abrasives, including physical make up and the conditions they will be used under.

The manufacturer of the abrasive should be able to give you guidelines on how their abrasives best work under certain conditions.

Always keep in mind the material you are abrading (concrete and

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aggregate, glues, mastics, coatings) has to work together with your abrasive. Not using abrasives properly will affect both their performance and life. Here are five additional factors to consider when choosing the right abrasive: Weight. The weight over the abrasives will affect how they function.

Too little weight and the abrasive will

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not cut efficiently or properly; too much weight may cause excessive wear. Too much weight over resin bond abrasives may also cause resin transfer resulting in a floor whose polished appearance may not be the result of the mechanical process but the result of creating a layer of shiny resin.

RPM. The RPM of the machine has to be properly managed. Lower grits work better at lower speeds. A lower grit run at higher speeds will not properly bite and abrade the surface but instead glide or skip over the surface. One of the ways to run higher speeds is by adding more weight, but you will need a machine and an abrasive that is designed to run under heavier weight and higher speeds.

Higher grits can be run at higher speeds because they are removing less material from the surface and do not need excessive bite with the surface. Running an abrasive not designed for higher speed will lead to resin transfer.

Rotation. If using a planetary head machine the directional rotation of the main head and satellite heads will affect how an abrasive cuts. When using a planetary head machine the main head rotates in

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one direction. The path of least resistance is for the satellite head to rotate in the opposite direction.

If both the main head and satellite heads can be set to rotate in the same direction a more aggressive abrasion will occur.

Tread. The tread or face of an abrasive comes in several different styles. You can have two different types of abrasives both being 100 grit.

One 100 grit abrasive may have twice as much surface contact than the other. Although they may both be 100 grit, the one with less surface contact will be more aggressive in how quickly it cuts and will also take longer to create a fully refined scratch pattern.

Speed. The speed at which equipment moves over the surface in a linear motion will dictate how

well the abrasive abrades the surface. Moving the machine too fast will not allow the abrasive to create a consistent, tight scratch pattern. Moving too slowly with an abrasive typically below 50 grit may cut too quickly and remove more than intended.

Understanding abrasives will allow you to provide a better product in a more efficient manner and give you the know how to effectively work with all the various types of concrete you encounter in the field.

Editor’s Note: This article has been updated from the original version, which first appeared in the January 2010 issue of Concrete Contractor.

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THE LAST PLACEMENT

By Brad Humphrey

The Trifecta of Mentoring Effective mentoring includes a motivated HR leader, a motivated mentee and a committed mentor

L

iStock

ove him or hate him, Dick “Dickie” Vitale, the extremely extroverted and often very colorful commentator for college basketball, is known for his over enthusiastically corny commentary on what a successful team needs to execute in order to win a game.

He often refers to his observations as “the trifecta of offense,” or “defense… baby!” Well, in the spirit of Dick Vitale, we’re going to address the “Trifecta of mentoring…Baby!”

While I admit that many formal mentoring programs do fail, I have found that three key elements must be in place to give the mentor and “mentee” (i.e. protégé), a fighting chance to see needed and profitable results. Before you throw your current mentoring effort away, or before you think that mentoring must only happen naturally, consider what I call the “Trifecta of mentoring.”

PART #1 DEMANDS A MOTIVATED & FOCUSED HR LEADER You don’t have someone who is motivated from head to toe about the power of mentoring? Scrap all of your effort to create a meaningful and sustainable mentoring process because it just will not happen. That’s how important this

leader is to the success of any mentoring process you try to implement.

If you have not yet begun a mentoring process internally but want to, start with this first role and get your hands on an HR leader who is sold on mentoring. This first element of the “trifecta” cannot be managed by someone who has only a small piece of time to devote to it—not to mention someone who is not 100 percent committed to the positive returns mentoring offers.

PART #2 DEMANDS A MENTEE WHO IS MOTIVATED & FOCUSED You place a less-than-motivated mentee into a mentoring program and you will see poorly attended meetings with their mentor. The mentee must be someone who wants to grow as a craftsman or professional. He or she recognizes that the potential gain from such a relationship offers new opportunities, new ways of thinking and new strategies to tackle future dreams.

To be a mentee, a person needs to demonstrate: • Consistent performance • A sincere hunger to learn more • The desire and capability to listen • The ability to put into practice what others have coached them to do with other responsibilities • Sustainability to stick with a process, task or problem solving • Respect for the company and for those who do have more knowledge and experience The mentee doesn’t have to be a perfect angel; in fact, it’s probably good if they're not. However, they do need to demonstrate a real enthusiastic streak to improve their own performance, insights and future.

PART #3 DEMANDS A MENTOR WHO IS COMMITTED TO TIME, PURPOSE & DISCIPLINE The final part of our trifecta is the role of the mentor. Without mentors you have no mentoring program.

Herein lies part of our dilemma for the mentoring strategy.

Many wise and experienced construction “gurus” are leaving our companies and industry. Some are leaving physically through retirement and some, unfortunately, are leaving mentally, simply “checking out” with three to five years left in their employment.

More contractors must work harder at helping their aging workers, at all levels, to renew their love for this great industry we call construction.

Contractors then need to “download” as much of their experience and wisdom into the younger workers as possible. This is no easy feat for sure, but it must be addressed.

Mentoring is still a great way to grow employees. For the many companies that have good experiences with mentoring, these employees will grow into the future contractors, field leaders and senior decision-makers for many lucky construction companies.

But mentoring isn’t easy. With the increased time commitments already imposed on construction leaders, getting those who can serve as mentors to adjust their schedule to work “another commitment” into their busy week will require all of the discipline that the mentor can muster.

However, the long-term success of any construction company might very well depend on such efforts.

Remember, mentoring is a great employee growth strategy…baby!

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