Concrete Contractor August/September 2016

Robotic Total Station Update

44 August/September 2016

Now available online and on your iPad!

Uniform Polished Concrete Starts with the Canvas

32

Creativity and Originality

Transform

the Zephyr Hotel 24

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August/September 2016 | Issue 5, Volume 16

WHAT’S INSIDE Photo Credit: Zephyr Hotel

Departments 4 Editor’s Letter 6 Legal Matters 8 Challenging the System 50 Foundation Q&A 42 The Last Placement

Cover Story 20 Creativity and Originality Transform the Zephyr Hotel How collaboration created an architectural transformation to illustrate the power of concrete in design.

Features

What’s Online

10 Specification Guides: Vibrating Equipment

Read these online exclusive articles at www.ForConstructionPros.com/ concrete.

A compilation of technical information when choosing your next concrete vibrator.

14 Selecting Compaction Equipment that Won’t Crush Your Profits To avoid downtime and maximize ROI, look for equipment that brings success, from site preparation to the finished work.

32 Uniform Polished Concrete Starts with the Canvas Proven techniques to avoid problems.

How to Cool Concrete During Placement

16 Inverter Generators Don’t buy the cheapest, buy what saves you the most over time.

44 Robotic Total Station Update How manufacturer’s are making them more contractor friendly.

40 40 Surface Grinder Do’s and Don’ts Six tips for contractors to realize how low speed grinders can be seen as a profitable and productive machine.

44

When project specifications required cooling of the concrete during the curing process for a high-profile construction project in downtown San Diego, the contractor was unfamiliar with the process and needed technical support. Search: 12237580

Can Recycled Materials Improve Concrete Performance While Reducing Emissions?

New research shows the chemistry of concrete systems can be improved to provide better performance, while reducing its carbon footprint.

Search: 12237436

www.forconstructionpros.com/concrete | August/September 2016 | Concrete Contractor 3

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EDITOR’S LETTER

The Future of

CONCRETE

E

arlier this summer, spearheaded by the American Society of Concrete Contractors (ASCC) and facilitated by the ACI Foundation’s Strategic Development Council (SDC), Concrete 2029 was launched as a strategic initiative to develop a vision and road map for the future of the concrete construction industry. According to Bev Garnant, Executive Director of the ASCC, the motivation for this endeavor is to secure the future of the concrete construction industry by getting in front of issues such as the misconstrued image of concrete, code struggles, loss of market share to other building materials, declining productivity, and a shortage of workers in concrete construction.

The initial workshop was held in May, prior to the SDC Technology Forum. The meetings were productive and those in attendance identified issues such as defining and improving in-place concrete quality, increasing workplace productivity, and improving industry promotion and perception.

Developing a vision and strategy is vital for the concrete industry to thrive in the future. Concrete 2029 will be holding a second workshop on September 7, in Salt Lake City, Utah. As a concrete contractor, this Facebook.com/ ConcreteContractor

Advisory Board

Ryan Olson, Editor ROlson@ ACBusinessMedia.com (800) 538-5544

is a great opportunity for you to get involved in the industry to make sure the future is bright.

For more information on how to participate, visit www.ConcreteSDC. org and get involved.

PLAN TO ATTEND CP&S IN OCTOBER Concrete Contractor is putting together the first Concrete Polishing and Staining Conference (CP&S), a three-day conference dedicated to polished concrete. The conference will take place October 20-22 in Milwaukee, Wisconsin.

If you’re a polished concrete contractor, you won’t want to miss the lineup of educational sessions we have planned. At the conclusion of the sessions, visit the exhibit hall to discuss what you learned with industry leading exhibitors who will be sharing the latest in products and technology. For more information or to register to attend, visit www.

CPSConference.com.

Follow us @ Concreteinsider

Kim Basham KB Engineering Cheyenne, Wyo.

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

Jim Baty Concrete Foundations Association Mt. Vernon, Iowa

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

Published by AC Business Media Inc.

Search: Concrete Polishing

Dennis Purinton Purinton Builders, Inc. East Granby, Conn.

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

www.ForConstructionPros.com/Concrete PUBLICATION STAFF

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Contributing Writers Senior Production Manager Art Director Audience Development Director Audience Development Manager ADVERTISING SALES (800) 538-5544

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PO Box 3605, Northbrook, IL 60065-3605, Phone: (877) 201-3915 Fax: (800) 543-5055 • circ.ConcreteContractor@omeda.com REPRINTS Vaughn Rockhold, (800) 538-5544, ext. 1248 or vrockhold@ACBusinessMedia.com LIST RENTAL Elizabeth Jackson, Account Executive, Merit Direct LLC, Phone: (847) 492-1350 ext. 18 Fax: (847) 492-0085 • ejackson@meritdirect.com AC BUSINESS MEDIA INC.

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Published and copyrighted 2016 by AC Business Media Inc. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording or any information storage or retrieval system, without written permission from the publisher.

CONCRETE CONTRACTOR (USPS 021-799, ISSN 1935-1887 (print); ISSN 2471-2302 (online) is published 7 times a year: January, February/March, April/May, June/July, August/September, October/November and December by AC Business Media Inc., 201 N. Main Street, Fort Atkinson, WI 53538. Printed in the U.S.A. Periodicals postage paid at Fort Atkinson, WI, and additional entry offices. POSTMASTER: Send address changes to Concrete Contractor, PO Box 3605 Northbrook, IL 60065-3605 August/September 2016, Issue 5, Volume 16 One year subscription to nonqualified individuals: U.S. 1 year: $35, 2 years: $70. Canada & Mexico 1 year: $60, 2 years: $105. All other countries 1 year: $85, 2 years: $160 (payable in U.S. funds drawn on U.S. banks). Single copies available (prepaid only) $10.00 each (U.S., Canada & Mexico), $15.00 each (International).

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4 Concrete Contractor | August/September 2016 | www.forconstructionpros.com/concrete

CONC0816_04-5_Editor.indd 4

Vaughn Rockhold, (800) 538-5544, ext. 1248 vrockhold@ACBusinessMedia.com Ryan Olson, (800) 538-5544, ext. 1306 rolson@ACBusinessMedia.com Kim Basham, Jim Baty, Brad Humphrey, David C. Whitlock, Joe Nasvik Cindy Rusch April Van Etten Wendy Chady Angela Kelty

Concrete Contractor is the Official Media Sponsor of the CFA Foundation Company Certification Program

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LEGAL MATTERS

Safety Matters OSHA is expanding its enforcement efforts using new approaches including seeking remedies for violations at sites not inspected, seeking information unrelated to the safety complaint that first brought them out to the employer, substantially increasing penalties, and adding to the employer burden of record keeping and reporting.

I

n a recent case OSHA sought abatement of safety violations at the company’s 170 locations nationwide, even though most of those sites were not inspected or even visited by OSHA regulators. This suggests that contractors may face penalties at numerous jobsites even if no safety complaint is ever raised.

While it is true that federal courts have generally limited OSHA’s information demands to those reasonably necessary to determine the subject matter of the complaint, OSHA continues to try to expand investigations into areas not covered by the complaint. Last October OSHA issued a policy guideline encouraging inspectors to look at broad-based safety compliance regardless of the complaint or reason for the inspection. This guidance was limited to the poultry processing industry, but one can easily see it expanding to other industries.

As a practical matter, limiting the inspector’s scope of inquiry may be very difficult to do short of litigating the matter, which is expensive and time-consuming.

Penalties for health and safety violations have not increased since 1990. That has changed now. Effective August 1, 2016, OSHA will implement a 78 percent increase in the penalty structure and in future years penalty amounts will be tied to the cost of living index. Just to put numbers out there: the penalty for a serious OSHA violation will increase from $7,000 to $12,744. For repeat and/or willful violators, the maximum penalty will increase from $70,000 to $125,438.

True, OSHA can impose a lesser penalty, but that requires bureaucratic cooperation and proof the maximum penalty would have a significant economic or social cost.

OSHA’s record keeping and reporting rules have recently changed also. Now, the rules specifically state any policy the employer has requires employees to report accidents or injuries must be reasonable and must assure employees of non-retaliation.

Although the statute itself prohibits retaliation against an employee who files a complaint, OSHA was previously powerless to do anything unless the employee complained of retaliation. Now, however, OSHA can penalize an employer on its own without an employee complaint. It remains to be seen how this new rule will affect employee discipline, post-incident drug testing, and safety incentive programs. OSHA has stated that employers cannot use these programs to deter or deflect safety complaints.

Also, the rule requires contractors to inform employees about the new procedure, telling them specifically they have the right to report work-related accidents and injuries and the

David C. Whitlock has over 25 year’s experience in business immigration, compliance, employment counseling and training. He is the founding attorney of Whitlock Law LLC and can be reached at (404) 626-7011 or at davidcwhitlock@gmail.com.

employer will not retaliate against them for so reporting. Again, you should document that each employee received this “training.”

Employers with 250 workers must submit information from the OSHA 300 logs, 300A Summaries, and the 301 Injury and Illness Incident Reports electronically. This will be phased in so that only the 300A Summaries must be electronically submitted by July 1, 2017.

The remaining forms will be submitted electronically by July 1, 2018.

Contractors with 20 to 249 employees must electronically report their 2016 OSHA 300A summaries by July 1, 2017.

In 2019, the reporting deadline will change to March 2. OSHA will post this data on an Internet site, presumably after redacting privacy details.

In addition to these rule making efforts, OSHA is taking a more proactive role publicizing advice and guidance to employers. For example, the agency recently conducted a webinar on the safety hazards of heat and lightning. Since nearly all contractors are working outdoors, your employees are especially at risk. OSHA maintains that lightning and heat are occupational hazards and that employers have a duty to protect their workers. Contractors need to be wary of lightning, storm and high winds risks and special OSHA rules regarding work from scaffolding, use of crane hoists, and work on top of walls.

For material relating to the dangers of heat stress, OSHA has the following website: https://www. osha.gov/SLTC/heatstress/.

Contractors are encouraged to remain aware of what OSHA is doing.

6 Concrete Contractor | August/September 2016 | www.forconstructionpros.com/concrete

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CHALLENGING THE SYSTEM

Contractors Make Recommendations Based on Experience

Ward R. Malisch, PE, PhD, FACI is concrete construction specialist for the American Society of Concrete Contractors. Reach him at wmalisch@ascconline.org.

Bruce A. Suprenant, PE, PhD, FACI, is technical director for the American Society of Concrete Contractors. Reach him at bsuprenant@bsuprenant. com.

Contractors citing previous experience should make their recommendations with the understanding the final decision will be made by the designer and owner.

W

e sometimes get calls from knowledgeable contractors who ask us questions similar to the following: I have a project in a northern state with 100-foot-long, eight-foothigh retaining wall, 50 feet of which is outside a building, with the other 50 feet inside the building. I’m thinking of telling the engineer that the wall should contain a thermal break to separate the inside and outside because, the differing exposure to temperature changes may cause problems. What’s your opinion?

I’m going to be placing a five-inchthick floor slab. The plans call for #4 reinforcing bars spaced at 18 inches center to center, and on three-inchhigh chairs. Plans show that all the bars pass through sawed contraction joints with none of them being cut at the joint. I believe this will cause outof-joint cracking because the contraction joints won’t open. Should I suggest that half of the bars be cut at each of the contraction joints?

We’ll be placing a four-inch-thick floor for a library, for which an architect has designed a decorative pattern for sawed construction joints.

The pattern results in some panels that are triangular in shape, with sharp acute angles. We believe the triangular panels will crack and want to suggest a normal jointing pattern with joints spaced at eight to 12 feet

apart to create rectangular or square panels. What’s your opinion?

We’re bidding a job that includes placing a concrete topping on an existing slab. The specifications require us, the contractor, to design the topping slab. That doesn’t seem right. Is it common for contractors to design part of the work they’re performing on a job?

RECOMMENDATIONS BASED ON EXPERIENCE Yes, contractors should share their experiences, especially the negative ones. There are three different ways to communicate your concern: ❶ State your concern based on your previous experience with the design. Nothing more. ❷ State your concern and offer an ACI or ASCC document that indicates recommendations. Then it is up to the designer and owner to consider those recommendations. ❸ State your concern and provide recommendations based on your experience, but with the understanding that the final decision will be made by the designer and owner.

AN APPROACH FOR THE FOUR EXAMPLES If contractors see something in the plans or specifications that they believe will result in a concrete performance problem, either during or after construction, shouldn’t they call attention to it? That’s true. But the

contractors don’t have to claim engineering knowledge to handle such cases. Let’s outline an approach for each of the four examples we cited.

The inside-outside wall In this case, having no thermal break is not an obvious error in the plans. The structural engineer may have taken into account the temperature differences between the inside and outside portion of the wall and the possible consequences. Or the architect may have decided the difference in temperature wasn’t going to create problems within the building.

Our advice, bring your concerns to the engineer or architect in writing—so you have a record. Then let the design professionals make this decision.

Rebar passing through a contraction joints You’re correct that restraint from the rebar may not allow the joint to open and cause out-of-joint cracking. But that may be the designer’s plan. This floor has an area of steel/ gross area of concrete equal to 0.22 percent. If more than about 0.1 percent passes through the joint, cracking at other locations is likely.

As a general rule, the continuation of larger percentages of deformed reinforcing bars should not be used across saw cut contraction joints or construction joints because they restrain joints from opening as the slab shrinks during drying, and this

8 Concrete Contractor | August/September 2016 | www.forconstructionpros.com/concrete

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increases the probability of out-of-joint random cracking (ACI 360R-10 p.28).

Some engineers, however, increase the amount of steel so there are more cracks, but the cracks are narrower and less likely to result in spalling. If that’s the case, however, sawing the joints is a needless expense. We’d suggest sending an RFI and noting that, in your experience, having that much rebar pass through the joints results in outof-joint cracking. Then ask if that is the intent. Attach page 28 of ACI 360R-10 and let the engineer confirm his original design or make changes.

Triangular floor panels created by jointing pattern We suggest an RFI noting that triangular-shaped panels are more likely to crack near the sharp acute angles, and note your concern for the increased cracking due to the jointing layout suggested. To support your concern you can cite excerpts from

ACI 302.1R-15 (“Contraction joints should be continuous, not staggered or offset.”), PCA’s EB075 4th ed. (“Joints should create panels as nearly square as possible…”), and ACI CCS1(10) (“When slabs are formed with very sharp corners, designers sometimes locate contraction joints at locations where concrete is most likely to crack.” (Fig. 8.6).

Contractor required to design a topping slab Concrete contractors have no responsibility for engineering design unless such responsibility is required by the contract documents. Contract documents can require licensed design professionals to design formwork and shoring, or to have responsibility for design and construction of precast concrete elements or of a cast-in-place post-tensioned floor system. Any other design requirements in specifications that shift design to the contractor

should be carefully considered during the bid, and excluded if they make the contractor uncomfortable.

THE FINAL WORDS The designer has more information about the specific project, and more expertise in design than contractors do. So if contractors see construction requirements that seem incorrect, their role is to state their concern and then confirm the designer’s intent in writing. By doing this they can help the owner or design professional, but are not providing design services or accepting any design liability.

Ed. Note: ACI 302.1R-16, ACI 360R-10, and CCS1 -10 can be purchased at www.concrete.org EB075, published by the Portland Cement Association, can be purchased at www.cement.org

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www.forconstructionpros.com/concrete | August/September 2016 | Concrete Contractor 9

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SPECIFICATION GUIDE: VIBRATING EQUIPMENT

Vibrating Equipment A compilation of technical information when choosing your next concrete vibrator.

1 Allen BP-50 Backpack Vibrator

Allen backpack vibrator units provide superior consolidation of concrete and feature interchangeable head and shafts with the quick disconnect system. Go anywhere backpack features a “speed-up” transmission that allows the engine to run at low RPM’s and still produce high VPM’s ForConstructionPros.com/12239590 Model

Product Size (LxWxH)

Weight:

Vibrations (rpm)

Power (hp)

Flexible Shafts (Length)

Flexible Shafts (weight – lbs.)

Head Diameter (inches)

Head configuration: Round or Square (hybrid)

Power (electric or gas)

Power VibePV 35HPU

N/A

N/A

N/A

1.3 hp

2’ to 10’

N/A

1” to 2”

Round

Gas

Model

Product Size (LxWxH)

Weight:

Vibrations (rpm)

Power (hp)

Flexible Shafts (Length inches)

Flexible Shafts (weight – lbs.)

Head Diameter (inches)

Head configuration: Round or Square (hybrid)

Power (electric or gas)

Power Vibe Pro PVP 35HPU

N/A

N/A

N/A

1.3 hp

1’ flexible shaft with rigid shaft extension

N/A

2”

Round

Gas

Model

Product Size (LxWxH)

Weight:

Vibrations (rpm)

Power (hp)

Flexible Shafts (Length - inches)

Flexible Shafts (weight – lbs.)

Head Diameter (inches)

Head configuration: Round or Square (hybrid)

Power (electric or gas)

BP50

N/A

29 lbs.

11,000 12,000

2.1hp

2’ to 21’.

N/A

N/A

Round

Gas

2 Atlas Copco SMART Electric Concrete Pokers

The 230-volt SMART electric pokers feature a radius of action that is 12 times the diameter of the poker heads, enabling them to work faster to remove air voids from concrete.

• Available with 1-7/8- and 2-3/16-in. poker heads • Can work in areas as large as 22 in. in diameter, minimizing the number of dips required • Comesvwith 32.8 ft. of electrical cable wand 16.4 ft. of hose, with longer hose options available ForConstructionPros.com/10838205

Model

Product Size (LxWxH)

Weight:

Vibrations (rpm)

Power (hp)

Flexible Shafts (Length - inches)

Flexible Shafts (weight – lbs.)

Head Diameter (inches)

Head configuration: Round or Square (hybrid)

Power (electric or gas)

SMART 40

590” x 4” x 4”

28.88 lbs.

12,300 vpm

.54 hp

16.4’

Tube Weight: 5 lbs.

(FLEXIBLE SHAFT N/A)

Tube Diameter: 1-5/8”

Round

Electric

Model

Product Size (LxWxH)

Weight:

Vibrations (rpm)

Power (hp)

Flexible Shafts (Length - inches)

Flexible Shafts (weight – lbs.)

Head Diameter (inches)

Head configuration: Round or Square (hybrid)

Power (electric or gas)

SMART 48

590” x 4” x 4

32.4 lbs.

12,300 vpm

1.25 hp

16.4’

Tube Weight: 9.26 lbs.

(FLEXIBLE SHAFT N/A)

Tube Diameter: 1-7/8”

Round

Electric

Model

Product Size (LxWxH)

Weight:

Vibrations (rpm)

Power (hp)

Flexible Shafts (Length - inches)

Flexible Shafts (weight – lbs.)

Head Diameter (inches)

Head configuration: Round or Square (hybrid)

Power (electric or gas)

SMART 56

590” x 4” x 3”

35.05 lbs.

12,300 vpm

1.57 hp

16.4’

Tube Weight: 11.5 lbs.

(FLEXIBLE SHAFT N/A)

Tube Diameter: 2-1/4”

Round

Electric

10 Concrete Contractor | August/September 2016 | www.forconstructionpros.com/concrete

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Equipment built on concrete experience.

Wacker Neuson makes a full range of professional concrete trowels ranging from the 24-inch edger to the 10-foot hydraulic rider. But that’s not all, we go the extra mile. With over 25 years of engineering and manufacturing experience, a team of national product specialist and a technical training academy, Wacker Neuson is the brand you can trust and your partner for the long run.

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SPECIFICATION GUIDE: VIBRATING EQUIPMENT

3 Chicago Pneumatic Electric Pokers

Designed for use in medium to high slump concrete, Chicago Pneumatic electric pokers are effective and efficient. Light and easy to handle, they provide the vibration needed to remove air voids in the concrete. Fast startup, a wide radius of action and rapid acceleration for removal of air voids add to the effectiveness. The electric motor is highly efficient and the low voltage helps protect the operator. The lineup includes the VPE 40, VPE 50, and VPE 60.

ForConstructionPros.com/12239612

Model

Product Size (LxWxH)

Weight:

Vibrations (rpm)

Power (hp)

Flexible Shafts (Length inches)

Flexible Shafts (weight – lbs.)

Head Diameter (inches)

Head configuration: Round or Square (hybrid)

Power (electric or gas)

Chicago Pneumatic VPE 40

N/A

4 lbs.

200 to 12,000 vpm

5 hp at 42V

33’ of cable, 16’ of hose, 49’ total reach, 1.6” diameter

N/A

N/A

Round

Electric

Model

Product Size (LxWxH)

Weight:

Vibrations (rpm)

Power (hp)

Flexible Shafts (Length inches)

Flexible Shafts (weight – lbs.)

Head Diameter (inches)

Head configuration: Round or Square (hybrid)

Power (electric or gas)

Chicago Pneumatic VPE 50

N/A

6.7 lbs.

200 to 12,000 vpm

5 hp at 42V

33’ of cable, 16’ of hose, 49’ total reach, 2” diameter

N/A

N/A

Round

Electric

Model

Product Size (LxWxH)

Weight:

Vibrations (rpm)

Power (hp)

Flexible Shafts (Length inches)

Flexible Shafts (weight – lbs.)

Head Diameter (inches)

Head configuration: Round or Square (hybrid)

Power (electric or gas)

Chicago Pneumatic VPE 60

N/A

11.2 lbs.

200 to 12,000 vpm

5 hp at 42V

33’ of cable, 16’ of hose, 49’ total reach, 2.4” diameter

N/A

N/A

Round

Electric

4 Minnich Back Pack Concrete Vibrator

The Minnich Back Pack Concrete Vibrator offers increased operator comfort and reliable performance without the use of an electric cord. Featuring a padded back and comfortable double-strap shoulder harness, the back-pack configuration reduces operator fatigue on longer jobs. A 1.5-horsepower Honda GX35 Mini-4 Stroke engine provides reliable power, with an allposition diaphragm carburetor for operation in any position without stalling.

ForConstructionPros.com/12239627

Model

Product Size (LxWxH)

Minnich Back Pack Concrete Vibrator

14” x 12” x 24”

Weight:

Vibrations (rpm)

Power (hp)

Flexible Shafts (Length inches)

16.9 lbs.

8,0009,000

1.3 hp

84”; 120”; 168”

Model

Product Size (LxWxH)

Minnich Hand Held Concrete Vibrator

12” x 9” x 10”

Flexible Shafts (weight – lbs.)

Head Diameter (inches)

Head configuration: Round or Square (hybrid)

Power (electric or gas)

7’ core & casing: 7 lbs.; 10’ core & casing: 9 lbs.; 14’ core & casing: 11 lbs.

3/4”; 1”; 1-3/8”; 1-3/4”; 2”; 2-3/8”

Round

Gas

Weight:

Vibrations (rpm)

Power (hp)

Flexible Shafts (Length inches)

Flexible Shafts (weight – lbs.)

Head Diameter (inches)

Head configuration: Round or Square (hybrid)

Power (electric or gas)

12.75 lbs.

8,0009,000

1.3 hp

84”; 120”; 168”

3’ bent 2’ flexible shaft: 8.15 lbs.

3/4”; 1”; 1-3/8”; 1-3/4”; 2”; 2-3/8”

Round

Gas

5 Rattle Stick Vibrating Adapter

The Rattle Stick is a cordless lightweight rechargeable float and walking tool surface vibrator that helps produce the best possible finish especially for lower slump mixes and decorative finishes.

Reduces hard trowel time by 50 percent and blends in color hardener easily. Simple snap pole connection into all your tools. Made in USA ForConstructionPros.com//12113054

Product Size (LxWxH)

Weight:

Vibrations (rpm)

Power (hp)

Flexible Shafts (Length - inches)

Flexible Shafts (weight – lbs.)

Head Diameter (inches)

Head configuration: Round or Square (hybrid)

Power (electric or gas)

Rattle Stick Vibrating Adapter 30” x 2.25” x 2.25”

4.2 lbs.

6,500

N/A

N/A

N/A

N/A

N/A

N/A

Model

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KA-4 High Frequency Pneumatic 6 Vibco Internal Concrete Vibrator A new addition to VIBCO’s High Frequency Pneumatic Internal Concrete Vibrator. It is a continuous duty, air cooled, low air consumption air operated vibrator.

• 15 in. (380 MM) long. 10 ft. (3 M) long flexible rubber hose standard • The vibrator speed 12,000 - 15,000 vibrations per minute.

ForConstructionPros.com/12239658

7

Model

Product Size (LxWxH)

Weight:

Vibrations (rpm)

KA-4

N/A

N/A

12,000 to 15,000

Power (hp)

Flexible Shafts (Length inches)

Flexible Shafts (weight – lbs.)

Head Diameter (inches)

Head configuration: Round or Square (hybrid)

Power (electric or gas)

N/A

10’ standard – other shaft lengths available

4”

Round

Compressed air operated

N/A

Wacker Neuson’s New Flex Shaft Vibrator Motors The new “M” motors, M1500 and M2500, combined with a variety of heads and shafts, provide optimum concrete consolidation for every type of application.

• The new M1500 and M2500 electric motors are lighter weight than previous models.

• Wacker Neuson’s flex shaft system allows contractors to combine a variety of flex shafts.

• The new M2500 motors is adaptable to all shaft and head combinations.

ForConstructionPros.com/12239679

Model

Product Size (LxWxH)

Weight:

Vibrations (rpm)

Power (hp)

Flexible Shafts (Length - inches)

Flexible Shafts (weight – lbs.)

Head Diameter (inches)

Head configuration: Round or Square (hybrid)

Power (electric or gas)

HMS-flexible vibration system

Motors: 12.3” x 6.1” x 9.1”

11.9 lbs.

N/A

2.0 hp and 2.5 hp

19.7” to 354.3”

3.3 lbs. to 33.3 lbs.

1” to 2.75”

Round and Hybrid

Electric

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www.forconstructionpros.com/concrete | August/September 2016 | Concrete Contractor

CONC0816_10-13_SpecGuides.indd 13

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PRODUCT FOCUS

By Darrell Engle and Tim Hoffman

Selecting COMPACTION EQUIPMENT that Won’t Crush your Profits Concrete contractors put a ton of faith into their equipment and tools. To avoid downtime and maximize ROI, look for equipment that brings success, from site preparation to the finished work.

E

quipment plays a vital role in compacting base materials and as a result, the quality and integrity of the finished concrete.

From tampers to large soil rollers, compactors come in diverse product lines with numerous applications. They compact materials around foundations for landscaping and even handle preparing soil for larger projects, such as parking lots. It’s not only important to choose one for what it can accomplish on a project, but also for what it can accomplish in terms of productivity and uptime.

SMALL EQUIPMENT, BIG RESULTS A variety of light compaction equipment, including plate compactors and rammers, make a good addition to an equipment fleet. Contractors can use the equipment on a wide range of

projects, from small patios to larger driveways. Selecting compactors that are dependable, as well as easy to use and maintain, ensures several years of use with routine maintenance. Such equipment also requires a relatively minimal investment. Generally, look for units with productivity-enhancing features that reduce servicing downtime and are highly maneuverable.

When faced with a bigger pavement job, such as a driveway, plate compactors are the best friends for ensuring a solid, deep base layer of granular soil for the concrete. Look for models that travel quickly, some as fast as 105 feet per minute, which helps complete larger projects fast.

Contractors also save time with models that have a compaction indicator.

This will help take out the guesswork of knowing when the ground is compacted and will prevent over compaction.

For compaction work on cohesive and granular soils in the narrowest of areas, including around structures and between plants, choose a rammer that allows operators to achieve maximum productivity. Lightweight units with narrow tamping feet — some as narrow as six inches—make it easy to maneuver close to obstacles.

BIG EQUIPMENT, BIG POTENTIAL. Light compaction equipment allows contractors to tackle smallto medium-sized projects, but with

larger soil rollers, contractors can Light compaction position themequipment, selves as a oneincluding plate compactors and stop source for rammers, are big applications good additions too, including to an equipment parking lots. Not fleet because only that, larger of the high ROI potential. soil rollers can Photo Credit: Atlas maximize time Copco Construction spent compacting Equipment soils, which saves on labor costs.

Whether renting or purchasing, contractors need to look for features on soil rollers that maximize productivity and up-time to complete projects quickly as well as accurately.

Cross-mounted engines on soil rollers sit perpendicular to the frame, rather than parallel. This allows technicians to easily reach all necessary components and the hydraulic pump inside the engine compartment so maintenance is easier and faster. Also consider features than can prevent maintenance.

14 Concrete Contractor | August/September 2016 | www.forconstructionpros.com/concrete

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BIG BLOCK NOW WITH VANGUARD EFI. PROVEN POWER AND MAXIMUM PRODUCTIVITY. Our Big Block engines now with Vanguard EFI offer easier starting and superior load pickup for your customers who demand more from their equipment and less from the gas pump. They combine up to 37 gross hp* with the smart technology of automotive-based, closed loop electronic fuel injection—delivering just the right amount of fuel needed to tackle the toughest jobs. *

Based on 3600 RPM per SAE J1940

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PRODUCT FOCUS Rammers’ tamping feet are as narrow as six inches, and most units are relatively lightweight so they’re easy for operators to maneuver, which enhances productivity as well as accuracy.

Photo Credit: Atlas Copco Construction Equipment

Contractors often use soil rollers for a good chunk of time, so if the operator needs to strain or bend to see the drum edge and working surface, it could impact their productivity and ultimately delay a project. Straining and bending can even take a toll on the operator’s body. Choose units with sliding seats and userfriendly controls that move with the operator to provide optimal visibility of the working surface and drum edge, as well as eliminate the need to lean or twist.

Also consider what it will cost to run the unit. Rollers with rpm-management systems can reduce fuel consumption as much as 15 percent by automatically idling the diesel engine after 10 seconds in neutral.

When it comes to new technologies, intelligent compaction has certainly made headlines. While the cost of the systems might not be a great fit for every concrete contractor, those who often work on larger projects, such as parking lots, may find the system pays off over time.

Having an IC system optimizes soil compaction by providing real-time data, such as pass counts and relative stiffness of the soil. For example, some IC systems use global navigation satellite systems to track the number of completed passes, and drum-mounted accelerometers measure the surface’s relative material stiffness. This means the operator can review stiffness results to minimize the number of passes almost immediately.

This minimizes the risk of under compaction and over compaction, which can be time consuming and costly to remedy. The system also allows the contractor to set project parameters, which alert the operator after achieving optimal compaction levels.

With larger soil rollers, look for equipment that maximizes operator productivity and up-time with features such as crossmounted engines.

Photo Credit: Atlas Copco Construction Equipment

From a quality assurance standpoint, contractors can use the data from IC systems to prove that compaction standards were met.

This minimizes the risk of costly litigation or having to restart the project.

When considering IC systems, look for units that offer excellent mapping capabilities, which show missed areas, spots that need additional passes, and where over-compaction occurred.

Also look for an IC system with accelerometers that measure the drums’ responses to ground conditions about three to five feet below the surface. That way, as surface density increases, the frequency response of the drum changes. The accelerometers measure that frequency change, which registers on

the display inside the cab. This shows the operator if additional passes are required or when he or she achieved optimal compaction.

AFTER THE SALE As with any equipment, manufacturer support after the initial sale protects the contractor’s investment and, in some instances, extends the service life of the machines.

Equipment training from the dealer or manufacturer maximizes operator productivity as well as reduces the risk of premature

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by

GOT CONCRETE? PREP, POLISH, MAINTAIN WE CAN HELP! Whether you need a light restoration or your floor needs more extensive repairs and grinding. Niagara has the equipment, tooling, training and know how to get the job done.

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Go cordless with Lavina’s two propane grinders the 25G-X and the 30G-X both are ideal for prep, grinding and polishing. Lavina also offers a 36-inch propane burnisher that is a unique “do it all” machine featuring a large 36-inch foot print – it can be used for light floor repair and restoration, polishing, burnishing and maintenance.

NEW! Lavina continues to be the industry leader in innovation: now introducing new quick change bush hammers for heavy surface prep. Quality tooling to tackle any job.

4 Service/Showroom Locations 8 Sales Locations www.niagaramachine.com info@niagaramachine.com CONC0816_14-19_ProdFocus.indd 17

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PRODUCT FOCUS equipment wear. Manufacturers might offer on-site training, which allows the crew to learn how to operate and maintain the equipment on their own jobsite. Most manufacturers also include operator’s manuals with the machines, but look for ones that also post them online. This allows contractors, operators and mechanics to access them 24/7 for questions that might come up during operation or maintenance.

Consider a manufacturer that offers a wide breadth of products.

This eliminates the hassle of sourcing a variety of machines from numerous manufacturers to complete an equipment fleet. Plus, it’s more convenient for contractors to order any replacement parts or materials, such as hydraulic oil. Some manufacturers might offer special financing options to make owning a variety of new machines financially possible.

For large projects, consider ergonomic soil rollers to keep operators comfortable, productive and satisfied. For example, sliding seats and userfriendly controls move with the operator to provide optimal visibility of the working surface and drum edge as well as eliminate the need to lean or twist.

Photo Credit: Atlas Copco Construction Equipment

CRUSH THE COMPETITION Selecting the right compaction equipment might seem like an easy task, but taking the time to look at how each feature impacts the overall operation can have big payoffs. From cross-mounted engines to compact footprints, it’s these features that feed a contractor’s productivity, uptime and, most importantly, profits.

Ed. Note: Darrell Engle is the Atlas Copco Product Manager for light compaction equipment. He can be reached at darrell.engle@us.atlascopco.com.

Tim Hoffman is the Atlas Copco Product Manager for rollers. He can be reached at tim.hoffmann@us.atlascopco.com.

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WORKSITE EQUIPMENT

By Joe Nasvik

INVERTER GE Don’t buy the cheapest, buy what saves you the most over time.

E

ven though inverter generator technology has been on the market since 1999, you probably aren’t aware it exists.

If you happen to own one of these generators, you may not be aware that it is an inverter model, or why it is different than other generators that have served us for several decades. Hopefully, after reading this article, you will seek out inverter generators because they represent the direction that generator technology is headed in the effort to produce “cleaner power.” Today, almost all electrical equipment incorporates microprocessors requiring clean power, and inverter generator technology does the best job producing this smooth, dependable electricity.

TRADITIONAL GENERATORS The generators we are most familiar with have three common parts: an alternator, an engine, and a control panel.

The alternator produces the electricity and has a field and an armature similar to an electric motor that produces the electricity. It is coupled directly to an engine with a governor to keep the alternator rotating at a steady 3,600 rpm in order to produce 60 hertz 120 volt current—the consistency of the current depends on maintaining 3,600 rpms. When a power tool is

plugged into the generator and turned on, the engine must apply more power to the alternator in order to maintain this rpm and supply the proper current. Good generators can accomplish this very rapidly; lower quality generators have more lag time and can cause damage to equipment during this interval when uncontrolled current is generated.

Engines for generators are usually four-stroke gas powered, but there are diesel and LP gas units also.

They typically operate at a set speed regardless of load while power is being delivered to equipment. Some feature idle down operation when there is no demand for power.

The third component is the

The most popular selling inverter generators are the 2,000 watt models.

They are lightweight, save on fuel costs, are quiet, produce very “clean” power, and two of them can be joined in parallel to produce twice the wattage.

Photo Credit: Honda

control panel which contains outlets for supplying power, fuses, switches to turn the engine on and off, and other features that provide information to the operator.

Tim Sheehan, National Accounts manager for Yamaha, Cypress, California, adds that conventional generators are usually packaged in an open tubular frame for protection.

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GENERATORS The engine and alternator are exposed so there are louder noise levels as a result. This type of generator is typically used on jobsites.

HOW INVERTER GENERATORS WORK Like conventional generators, inverter generators also have an engine and an alternator, or alternator-like device. Thomas Pernice, Industrial Marketing Administrator for Honda Power Equipment, Alpharetta, Georgia, says Honda introduced the first inverter generator in 1999, building the alternator into the engine’s flywheel to reduce weight and size.

Inverter generators initially create three-phase AC power which is then electronically converted to DC power by the generator’s inverter. The invertor then converts the power back to AC current with a “pure sine wave”— very high quality power suitable for use in equipment using microchips and microprocessors (in other words, almost everything we use today).

Inverter generators create very smooth power, an advantage being that equipment using this power has a longer life as a result. Pernice notes that appliance dealers often see a spike in refrigerator sales (refrigerators require high quality power) after storms causing power outages because homeowners often generate temporary power with low-cost, low quality generators.

One of the great benefits of inverter generators is that they can produce current at any rpm; the engine does not have to operate When deciding on the right size generator to buy, find out what the starting wattage requirement are for the tools it will power.

at 3,600 rpm to produce 60 cycle current. The inverter electronically converts the current to 60 hertz 120 volt power. So, for instance, if you plugged in a 200-watt tool battery charger, the generator might only need to run a little faster than idle speed to produce the electricity needed; the engine rpm is adjusted to produce only the power needed by the power demand. This saves a significant amount of fuel, reduces noise, and significantly increases engine life.

Like conventional generators, the third major component of an inverter generator is a control panel which functions similarly to traditional ones.

Coupled with the fact that inverter generators often run at lower rpms, they also are usually enclosed with insulated panels, making them even less noisy.

DUAL POWER OPTION Companies like Honda and Yamaha include electronics in their products, allowing you to connect two similar inverter generator units together in parallel with a wiring harness that makes it possible to power equipment with twice the wattage. By combining two, 2,000watt generators, the output is 4,000 watts—the same as powering equipment on a 4,000-watt generator. Sheehan says people like this option because it’s easier to carry a generator that weighs 44 pounds versus one that weighs 150 pounds, and it’s easier to store them.

PURE SINE WAVES In the U.S., AC current changes direction by design 60 times per second, referred to as 60 hertz or 60 cycles. A graphic representation of

STARTING WATTS FOR COMMON CONSTRUCTION TOOLS Tool

Running Watts

Starting Watts

AIR COMPRESSOR 1/2 Horsepower

975

1600

1 Horsepower

1600

4500

1400

2300

1800

3600

Circular Saw 7-1/4” Concrete Saw

CONCRETE VIBRATOR 1/2 Horsepower

840

840

1 Horsepower

1080

1080

1230

1260

Demolition Hammer

DRILLS 3/8”, 4 amps 1/2”, 5.4 amps

440

600

600

900

Pressure Washer, 1 hp

1200

3600

Hammer Drill

1200

1200

Table Saw, 10”

1800

4500

www.forconstructionpros.com/concrete | August/September 2016 | Concrete Contractor 21

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WORKSITE EQUIPMENT very good power shows it as a mathematical curve of repetitive oscillation—a smooth, constant curved line on a graph; the smoother the curve the better is the power. If the curves on the graph have spikes or "blips" in the curve, it indicates a fluctuation in the power, a condition that can be harmful to both the generator and the device receiving electricity.

Generator manufacturers use various means to manage this graphic curve.

Conventional generators produce a sine wave mechanically by maintaining alternator speeds at 3,600 rpm.

Inverter generators maintain proper sine waves electronically and currently produce the very best power.

WHEN POWER DEMAND IS TOO HIGH If you plug in too many devices or one that exceeds what a generator can supply, a spike of electricity can occur, and the resulting current can be harmful

to equipment.

So, generator manufacturers use electronics to shut down power output to prevent damage to equipment. Also, tools and equipment often have a greater power demand when they start up, and these “reactive loads” can require up to three times more power during the start-up phase than what is needed to run the device.

This can cause generators to shut down. But there are ways manufacturers try to overcome start-up demands.

Pernice says Honda generators can run at full demand for short intervals, producing more start-up power.

Sheehan says their battery started generators can take power from the battery during start-up periods.

ADVANTAGES OF INVERTER GENERATORS • They produce the highest quality power of any small generator on the market today.

• They significantly reduce fuel costs.

• They operate at low noise levels.

• Maintenance is low, primarily engine oil change.

• They have longer life expectancy.

• Two of them can be joined together to double power output.

• They are lighter and easier to move around.

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22 Concrete Contractor | August/September 2016 | www.forconstructionpros.com/concrete

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The most popular selling inverter generators are the 2,000 watt models. They are lightweight, save on fuel costs, are quiet, produce very “clean” power, and two of them can be joined in parallel to produce twice the wattage Photo Credit: Yamaha

When demand exceeds what a generator can produce, inverter generators disengage before there is damage to tools or appliances. This usually happens while the engine is allowed to keep running.

GENERATOR SIZES Inverter generators started with the introduction of 1000-watt units, introducing larger and larger units with time. Currently, both Honda and Yamaha offer models between that and 6,300 to 7,000 watts at the upper end.

COST

WHAT THE FUTURE HOLDS

Many contractors put cost at the top of their list, so they dismiss inverter generators because they can cost more than double that of traditional models. But, like many things, one should consider cost in terms of the life of the purchase, not just the first cost. When viewed this way, you can save money purchasing inverter generators because they consume less fuel, require less maintenance, don’t damage tools and appliances, and have longer life cycles. Sheehan says that when marketing studies are conducted, people are often asked what they owned before this purchase. “There are many low quality products mentioned,” he says. “But they buy inverter generators because they want quality and reliability.” He urges people to do their homework and make purchases based on life costs and value.

Inverter generator technology is the direction that companies like Honda and Yamaha are headed with their product lines because they produce very high quality current, are lighter, make less noise, and are more fuel efficient. They continue to introduce higher and higher wattage inverter generators. The need for cleaner power also is being driven by tools and equipment that depends increasingly on microelectronics.

In the future, will there come a time when generators are no longer needed? With the rapid growth in battery technology, Pernice wonders if batteries will be combined with inverters to produce power for jobsite needs. The future will probably include fuels other than gas and diesel too—perhaps even fuelcell generators which have no moving parts.

Stick with

Weld-Crete®—The pale blue bonding agent with over 60 years of superior performance in the field.

Simply brush, roll or spray Weld-Crete® on to concrete or any structurally sound surface. Then come back hours, days or a week later and finish with new concrete, stucco, tile, terrazzo, other cement mixes or portland cement plaster. Plus Weld-Crete’s® low VOC content significantly reduces airborne pollutants that affect health and the environment.

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Creativity and Originality Transform the How collaboration created an architectural transformation to illustrate the power of concrete in design.

By Ryan Olson

T

he city of San Francisco is in constant movement as the technology hub of the world, and the crown jewel city of Silicon Valley.

With this coveted distinction also comes world-class architecture and construction projects. The office of Jett Landscape Architecture + Design, and specifically the founder Bruce Jett, was called upon by the developer to create an updated hotel venue that would integrate the unique aged and nautical spirit of Fisherman’s Wharf and also add a touch of elegance, appreciated by the younger technology crowd that frequents San Francisco. The old hotel was the Radisson Fisherman’s Wharf and the new hotel has become the Zephyr Hotel.

Jett is a renowned San Francisco Bay Area Landscape Architect and he immediately called upon his friend Michael Price, the owner of Bay Area Concretes (BAC) and PolishedCrete, to help him turn his architectural design vision, into a beautiful concrete hardscape. Jett and Price have

Zephyr H

collaborated on exceptional architectural concrete designs and projects for the past 20 years.

These men are both pioneers of new concrete products and technologies, in that Price brings new ideas and products to market while Jett and his team design them into real world developments. Bay Area Concretes typically installs the vision. This collaborative formula has worked well for them for years and thus here again an artistic idea has once again materialized into an award winning concrete project.

You will notice creativity and originality in concrete are present throughout this project. Jett wanted to achieve the look of worn nautical and distressed seaside paving elements within a unique and warmly inviting hardscape interior courtyard. He also wanted the exterior to flow well into the interior environment and vice versa. He designed abstract shaped concrete walls

throughout the project, which would have a distressed seaside appearance, yet be structurally sound and uniquely artistic in final appearance. The Bay Area Concretes team worked for several weeks to develop the look and finally came up with a

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With the EcoSand finish system the “acid washed jeans” look is integrated into the hardscape, in many areas, taking the form of a family “Board Game” of different checkered paving colors, that create a meandering pathway pattern within the enclosed courtyard hardscape paving.

r Hotel Photo Credit: Zephyr Hotel

The PolishedCrete team working with Jett Landscape Architecture + Design created a whimsical graphic that resembles a “swirl” effect within the polished concrete surface.

Photo Credit: Danika Briggs - Bay Area Concretes Inc.

means and method to achieve the distressed walls.

“We used a variety of surface retarders and carrying vehicles for these retarders, that were integrated into the form work of the walls. Many mock-ups were constructed in our

shop to create the effects," Price says.

“Bruce had explained the wall look he was after as “Distressed Beirut” to me and only because of our long history together was I able to envision the look he had in his mind.”

The hardscape utilized the

exceptionally diverse and patented product called Aggretex. Aggretex is a bagged mix architectural concrete product that can be blended with special sands, exotic aggregates and glass aggregates to create any look in concrete, that a designer can visualize. Aggretex surfaces can be exposed, ground, or polished. To continue the seaside-distressed theme into the hardscape, Bruce and Mike used Aggretex to provide both subtle colors in four to five different tones, and more importantly an aggregate/ sand tip exposure blend that would be predictable throughout the project. The technique used to expose the Aggretex pre-colored surfaces was the EcoSand system. This is an environmentally friendly system of surface exposure utilizing surface abrasion machines or grinders and Hepa filtered vacs to eliminate the

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PolishedCrete utilized the Prosoco Consolideck LF Densifier and LS Guard to provide the lobby and inside gaming center with an 800 grit level diamond polish.

Photo Credit: Zephyr Hotel

To continue the seaside-distressed theme into the hardscape, contractors used Aggretex to provide both subtle colors in four to five different tones, and more importantly an aggregate/ sand tip exposure blend that would be predictable throughout the project.

Photo Credit: Zephyr Hotel

need for a sandblaster on newly placed concrete projects. This final finish look was this time described to Price, by Jett in early design collaborations stages as the “acid washed jean look”. To achieve this look the BAC team again went to work in their R and D laboratory and went through countless poured concrete samples until they achieved the approved look. With the EcoSand finish system. You will notice that this look is integrated into the hardscape, in many areas, taking the form of a family “Board Game” of different checkered paving colors, that create a meandering

pathway pattern within the enclosed courtyard hardscape paving. This effect was achieved via randomly splashed liquid retarders in different levels of reveal, during placement of the Aggretex paving types. Topcast and SolomonBrickform’s Surface Deactivator were the retarders of choice, on this particular project, and used with the EcoSand exposure system. In addition to these concrete surface-revealing techniques, BAC used certain custom architectural tooling to abrade the concrete surfaces of both the walls and hardscapes, to different artistic levels and in

small controlled areas. Some of these tools are available through Engrave-A-Crete and specifically the BAC Artistic Team used the both the Barracuda and the Wasp concrete engravers.

Mike Price proudly states that “Exceptional communication and extreme detail is the key to success, in any architectural concrete project”.

Bay Area Concretes is the only remaining original Bomanite stamped concrete paving contractor, in the world, and has been stamping concrete with the Bomanite brand since 1966 – longer than anyone stamping concrete today. As such, Michael was able to convince Bruce and his design team to integrate a small amount of Bomanite stamped concrete, into the Shuffle Board game location of the exterior hardscape. There is actual ShuffleBoard woodwork in the middle of the board game location (see Picture), and then a Bomanite Boardwalk Plank imprinted concrete around this area. Bay Area Concretes used QC Durango Tan, Color Hardener in this area flashed with several other similar color hardener tones to create a natural looking and permanent stamped concrete “wood” surface. Michael Price says his two “go-to” brands of

26 Concrete Contractor | August/September 2016 | www.forconstructionpros.com/concrete

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The LAVINA 25LM-X self-propelled grinder features a second motor that propels the machine forward with NO remote control device and NO effort from the operator. It grinds and polishes at a constant speed, minimizing the risk of operator’s mistakes and improving the consistency of the floor finish.

L25LM-X 25� work path 15 hp motor 220 V or 480 V 500 lbs grind. pressure

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Color Hardener are QC Construction Products and Brickform and that these leading labels are used in 90 percent of his stamped concrete projects.

In addition to the beautiful exterior hardscapes, you will also notice there is beautiful polished concrete, that flows from the interiors of the Hotel.

The polished concrete was installed by Mike’s other company PolishedCrete.

PolishedCrete was created by Mike in 1999, just when diamond polished concrete was simply an idea and only being installed on a limited basis. Mike saw the opportunity to help create the next big market in architectural concrete finishing, just as they had done with the Bomanite stamped concrete model, back in the late 60’s. Since then, PolishedCrete has grown into the largest Union Labor concrete diamond polishing company in the nation. PolishedCrete employees SASE grinding machines along with some HTC and some Innovatech Diamond

Grinders and Polishers, among others.

Blastrac plays a large role withing the PolishedCrete business as well as they employ several models of bead blasters. At PolishedCrete the go-to vacuum equipment is typically manufactured by Ermator.

The unique graphic effect that is depicted herein, was applied over the diamond polished final concrete finish. PolishedCrete utilized the Prosoco Consolideck LF Densifier and LSGuard to provide the lobby and inside gaming center with an 800 grit level diamond polish. The concrete surface was ground to a medium level, honed, refined, and polished to perfection. In addition, the PolishedCrete Team working with Jett Landscape Architecture + Design created a whimsical graphic that resembles a “swirl” effect within the polished concrete surface. This artistic technique was achieved utilizing a product by Skudo USA called “HT”. This is normally a protective mat for polished concrete surfaces and other architectural concrete Bruce Jett designed abstract shaped concrete walls throughout the project, which would have a distressed seaside appearance, yet be structurally sound and uniquely artistic in the final appearance.

Photo Credit: Danika Briggs - Bay Area Concretes Inc.

Concrete Contractor: Bay Area Concretes, Inc. - www.bayareaconcretes.com PolishedCrete www.polishedcrete.com Landscape Architect: Jett Landscape Architecture + Design www.jett.land Concrete - US Ready Mix - Central Concrete Surface Finish - Aggretex Surface Retarders - Top Cast Mastic Joint Sealant - Sika Diamond Polish Densifyer and Guard Prosoco Polishing Equipment - SASE Diamonds - ProCrete Resources Skudo USA - Protection Membrane for Polish scope and Art Cure & Seal - Davis W1000 Color Hardener - QC Construction Products Affiliation for Bay Area Concretes Decorative Surface Solutions Group

finishes, during construction.

However the PolishedCrete team saw an opportunity to use this material as a graphic sandblast template material, which in turn created a beautiful artistic and undefined frayed edge to the actual concrete graphic.

Once the whimsical swirled graphic was in place the PolishedCrete team employed a Blastrac 10” self propelled shot blasting system to create the differential in surface texture from the 800 grit level Diamond Polished Concrete, in the shape of the graphic. The final result is both unique and stunning and carries to the Aggretex exposed EcoSand exterior paving area seamlessly.

BAC hopes to win several awards surrounding this project on the paving side and Jett Landscape Architecture + Design hopes to win awards on the design side of the equation, in the coming months. Michael Price states, “Bay Area Concretes is currently enjoying our 50th year in business and the limits to architectural concrete design seems to have less and less boundaries with each passing year.”

A small amount of Bomanite stamped concrete was integrated into the Shuffle Board game location of the exterior hardscape. There is actual ShuffleBoard woodwork in the middle of the board game location, and then a Bomanite Boardwalk Plank imprinted concrete around this area.

Photo Credit: Zephyr Hotel

28 Concrete Contractor | August/September 2016 | www.forconstructionpros.com/concrete

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FLATWORK

Polished Concrete Starts with the Canvas Uniform

Proven techniques to avoid problems.

By Denny Bartz, Pat Harrison, and Bruce Suprenant

W

ant a stunning polished floor where everyone is amazed at the results? If so, you need to make sure the canvas—the installed concrete slab—is appropriate because polishing does not necessarily eliminate, or may actually accentuate, imperfections in the existing slab. To avoid revealing these imperfections when polishing, consider these proven techniques, based on our experience at over 100 polished concrete floor installations. The means and methods described here will assist contractors in satisfying project specifications and guarantees happy architects and owners.

MINIMIZE THESE CANVAS IMPERFECTIONS Although there are many different imperfections in the concrete canvas that can show through after polishing, we want to share proven techniques to minimize or eliminate imperfections in four major categories: • Differential aggregate exposure – FIGURE 1.

• Difference in surface finish density – FIGURE 2.

FIGURE 1 - Bump Cutting: Differential aggregate exposure due to bump cutting, scraping the paste off the high spots and depositing it in the low spots. When polishing, the aggregate in the high spots will be exposed first.

Photo Credit: SSI

FIGURE 2 - Minimize Hand Finishing: Difference in surface finish density results from hand versus machine finishing.

Note the difference in the polished surface along the edges where the worker was hand finishing versus the polished surface where the surface was machine finished.

Photo Credit: SSI

32 Concrete Contractor | August/September 2016 | www.forconstructionpros.com/concrete

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FLATWORK • Effect of saw cutting – FIGURE 3.

• Influence of curing – FIGURE 4.

Minimizing or eliminating imperfections in these four categories will result in a dramatic improvement in the final polished floor. And here is how.

DIFFERENTIAL AGGREGATE EXPOSURE The overall aggregate size and the blend of coarse to fine particle content should be carefully FIGURE 3 - Residue and Scratches Below Plate: The effect of saw cutting is shown on the polished surface when the saw cut residue is not removed by an attached vacuum, specifically manufactured for the saw.

Photo Credit: SSI

FIGURE 4: The influence of curing illustrated when using a curing cover where the wrinkles have not been removed. The wrinkle locations will show when the slab is polished.

Photo Credit: SSI

FIGURE 5 - Discoloration from Tape Lines: The impact of protection is clearly shown by the discoloration of the tape lines after he floor is polished. What everyone thought would provide excellent protection, still turned out to show through on polishing. Be very careful with even the smallest of details when providing protection.

Photo Credit: SSI

considered for concrete materials that will be polished after installation.

If a smaller nominal maximum size aggregate and a higher sand content is desirable to achieve a more uniform fine aggregate exposure when polished, the designer should consider closer joint spacing to accommodate potential higher material shrinkage and minimize longterm joint widening.

Placing concrete in piles stacks the aggregate at these locations.

Workers then use a come-along or power screed to move concrete from

the top of the pile to distribute across the subgrade. However, what is being distributed is not concrete with a uniform aggregate distribution. Thus, when the floor is polished, the result is differential aggregate exposure at the surface. Aggregate stacking most often occurs when placing concrete by buggy or by pump when the pump hose is left in one spot. To minimize aggregate stacking during concrete placement, it’s preferable to place the concrete directly from the truck. If pumping is necessary, make sure the pump hose is not left in one spot during concrete discharge.

Uniform consolidation is important, as leaving a vibrator in one place too long separates the aggregate from the paste just enough so that these locations are visible during polishing.

Make sure the vibrator handlers understand this will ultimately be architectural concrete and they need a uniform, consistent vibration plan. This should include vibrators of the same size and frequency, vibrator insertion spacing, and vibration time.

Bump cutting removes paste from high spots and deposits it in low spots.

Thus when polishing over the high spots, aggregate at this location is exposed sooner than when polishing over the low spots that has more paste covering the aggregates.

Minimize or eliminate bump cutting from the finishing process. Use pan floats to obtain the floor flatness needed for polishing.

Footprints push aggregate lower,

34 Concrete Contractor | August/September 2016 | www.forconstructionpros.com/concrete

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FLATWORK bringing more paste to the surface and this difference can be seen during polishing (Figure 6). Minimize walking on the slab at an early age where the footprint can cause this issue. When hand screeding, pulling either a straight edge or vibratory strike off, walking ahead of the screed will depress the aggregate, potentially leaving differential aggregate exposure when eventually polished. Therefore, it is preferable to use a strike-off method that does not require standing in plastic concrete.

Use a roller tamp to seed the coarse aggregate below the surface.

Directly after the initial strike-off, roll a 36 inch minimum width, double roller tamp, prior to channel floating.

At the slab perimeter, use of a jitterbug will provide uniform coarse aggregate embedment.

DIFFERENCE IN SURFACE FINISH DENSITY Minimize hand finishing at pour edges, near walls and around columns and penetrations as these will polish differently than surfaces that are machine finished. At pour edges, use a beveled form edge with supporting stakes below the top form surface. Machine finish over the form edge as shown in Figure 7. Use a walk-behind edge finishing machine, with rotating guard ring, if necessary to get close to concrete slabs placed adjacent to walls. Always try to ride-on machine finish as close as possible to columns, penetrations and construction joints.

Avoid a burnished steel trowel finish that increases the potential for mottling and difficulty in uniformly polishing the slab. Perform machine troweling with plastic (Teflon) blades which provide a more uniform

FIGURE 6 - Footprints Seed Aggregate: Footprints push aggregate lower, bringing more paste to the surface and this difference can be seen during polishing.

Photo Credit: SSI

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surface finish than steel trowel blades.

Finally always check the machines for mortar because if it falls off and gets finished in to the concrete they will leave scratches that will be visible when polished.

EFFECT OF SAW CUTTING Form contraction joints with an early-entry power saw using a dry-cut blade. Use a vacuum (Figure 8) attached to the saw to remove saw cut residue. The earlyentry saw minimizes out-of-joint cracking due to delayed sawing, but the residue must be removed, and allowed to accumulate below the skid plate, or it will discolor the concrete when cured. This picture-frame discoloration of the concrete panels typically cannot be removed from polishing.

FIGURE 7 - Finish Over Beveled Form Edge: Machine finish over the pour edges by using a beveled form edge with supporting stakes below the top form surface.

Photo Credit: SSI

FIGURE 8 - Form contraction joints with an early-entry power saw using a dry-cut blade with a vacuum to remove saw cut residue, otherwise a stain from the residue will show when the concrete is polished.

Photo Credit: SSI

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www.forconstructionpros.com/concrete | August/September 2016 | Concrete Contractor 37

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FLATWORK Adhering the loop fabric side of a Velcro fastener strip to the bottom of the saw skid plate will also minimize scratching from any debris that is not removed from vacuuming.

INFLUENCE OF CURING Use moisture-retaining cover cure blankets (poly-backed cellulous covers absorb and retain the most moisture). Saturate the concrete surface for 30 minutes, then slowly unroll the blankets while continuing to saturate the absorbent side.

Wrinkles must be eliminated in the cover with a broom or roller, or they will create surface discoloration that cannot be removed when polished.

Adequate water below the blanket is necessary to remove all wrinkles and air voids. Salts will be brought to the surface through bleed channels

TEMP

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during the curing period. Therefore, while removing the curing covers, clean the surface. Scrub immediately, and as often as necessary, to remove all laitance and residue in a soluble state, prior hardening of materials that can discolor the slab surface.

PROTECTION WOES The canvas is perfect—it’s ready to be polished but wait, are those oil stains resulting from scissors lifts and forklifts that weren’t diapered?

And where did those scratches come from? While the concrete contractors might install a great canvas he can’t control the work of other trades. The general contractor or construction manager must step up to protect the floor and enforce work limitations or restrictions for all trades. A slab protection plan should be developed

and distributed for adherence by all sub-contractors and vendors working around or near the exposed concrete slabs. The protection is important to ensure the canvas, once placed, remains suitable for polishing.

ESTABLISH MEANS AND METHODS AT THE PRECONSTRUCTION MEETING The design team usually presents the important specification aspects of the particular work at the preconstruction meeting. Then they listen as the contractor presents his means and methods to accomplish the specification requirements.

Present the means and methods discussed here to show the design team and the owner, you are ready for their important job.

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Calculates concrete maturity; helps estimate concrete strength.

38 Concrete Contractor | August/September 2016 | www.forconstructionpros.com/concrete

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TECHNICAL Surface Grinder

Do's and Don'ts Six tips for contractors to realize how low speed grinders can be seen as a profitable and productive machine.

by Dennis Von Ruden

W

Contractors will have a much more pleasant experience operating their low-speed surface grinders if they are aware of proper operating techniques.

ith the introduction of high-speed diamond grinders in recent years, many contractors have tossed other types of equipment aside, hoping that the new, flashy machines will be a catch-all for concrete polishing and grinding applications. As these new machines burst onto the scene, many hopped on the bandwagon, figuring that if they don’t use the biggest and fastest machines available, then they are falling behind the competition.

However, contractors should be familiar with all items in their inventory, and they must focus on providing the correct solutions for application challenges, rather than being distracted by the latest hype. The answer to the question at hand may not always be the newest machine, but instead old faithful.

Photo Credit: General Equipment

HIGH AND LOW Over the years, there have been countless instances where one technology was replaced by another…The cassette tape gave way to the compact disc…The pager became virtually obsolete after the invention of the cell phone. But while some may be ready to replace their low-speed surface grinders with high-speed diamond grinders, they must first understand

the benefits of both machines.

Let’s start by considering highspeed grinders. They became a huge buzzword within the industry as the growth of concrete polishing jobs exploded. Although the machines came with a steep price tag, many people were impressed by the newfound ability to quickly tackle

concrete grinding and polishing jobs.

Suddenly, everyone could work like the pros…or could they?

With the development of a quicker machine, some may wonder why anyone would still use a low-speed grinder for concrete grinding and polishing. Can’t a high-speed unit do the same job more quickly? The answer

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is yes, but quicker isn’t always better. With speed comes the increased risk of inflicting costly damage to the surface, especially when the end user isn’t a well-trained professional. Lowspeed grinders, however, work more slowly so the operator does not accidentally remove too much material or lose control.

Although low-speed grinders have been available for almost 50 years, the continuous development of new attachments makes them an extremely versatile machine—even more so than high-speed diamond grinders. Not only are the machines capable of grinding concrete, but new polishing attachments, such as General Equipment’s Pro Polish system, also allow them to complete polishing applications. Additionally, since high rotational speeds make it much more difficult for a machine to penetrate surface coatings, lowspeed grinders are the only practical option for removing them. And while concrete polishing is the fad for now, the demand for surface coating removal will always remain high.

thousandths of an inch. Therefore, if an end user wishes to remove a half-inch of concrete on a 10,000-square-foot floor, a low-speed surface grinder is not the ideal machine.

USE DON’T: INCORRECT POWER SOURCES As obvious as it may seem, make sure that the unit being used has the

correct type of power source for the location. Engine-powered grinders are typically the best option for outdoor applications, since electric-powered units won’t work at an outdoor location that has no electrical outlets. Electricpowered machines also won’t suffice at indoor locations that don’t have the correct electrical power available.

In these cases, a propane-powered machine might be the ideal choice.

DIFFERENT STROKES FOR DIFFERENT FOLKS Of course, both types of grinders have their place in the industry. As mentioned, high-speed machines are typically suited for well-trained professionals, while low-speed grinders work well for small contractors and do-it-yourselfers, as well as anyone needing to remove surface coatings.

But since many contractors have reduced their emphasis on the use of low-speed surface grinders, here are a few things that should and shouldn’t be done in regards to these machines. By understanding these tips, you are well on your way toward achieving better results.

THE JOB DO: UNDERSTAND AT HAND Low-speed surface grinders may be versatile, but they are not a solution to all removal applications. For example, as a grinder they are designed to remove a minimal amount of concrete from the surface—as little as a few

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Since electric-powered units often have high amperage and voltage requirements, it is important to understand whether the machine needs a 115- or 230-volt power source and if it requires a 15- or 20-ampere circuit (This data is stated on the electric motor data plate). Then, if an extension cord is used, it should be rated to allow sufficient electrical flow according to the motor specifications. It should also be no longer than necessary, as cord length affects electrical resistance and voltage loss. If one is unaware of this knowledge, it is common for many to melt an inadequate extension cord that they bought from a big-box retailer.

UNDERSTAND THE DO: OPERATION OF THE MACHINE Contractors will have a much more pleasant experience operating their lowspeed surface grinders if they are aware of proper operating techniques. For example, extra weight, such as cinder blocks or sandbags, can be added to the machine in order to increase the material removal rate. This applies to almost every attachment configuration with the exception of wire brushes.

Since most low-speed grinders are designed for the addition of weights, check the owner’s manual for the manufacturer’s suggestions.

Also, many people try to increase the material removal rate by pushing and pulling the machine back and forth.

Instead, a more effective technique is to slowly pivot the machine about its wheels.

THE DON’T: USE WRONG

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Manufacturer customer service representatives receive calls every day from operators who are not satisfied with their surface grinder’s results, and the problem is often caused by the use of an incorrect attachment. For example, one of the most common mistakes is trying to use silicon-carbide stones to remove or grind floor coatings. The stones will work for only a short while before their pores clog with material and stop being

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ECHNICAL effective. In this case, scraper attachments may work best. On the other hand, scrapers will not work when trying to remove concrete.

Over the years, many types of attachments have been developed to meet the needs of various applications, and most manufacturers post information on their websites regarding the proper use of attachments. Unfortunately, many end users fail to educate themselves and, consequently, fail to achieve the desired results.

Educating yourself about the different types of attachments available and what attachment works best for a specific application will lead to the desired results you are looking to achieve.

Photo Credit: General Equipment

MATERIALS DO: DISPOSE PROPERLY

With today’s strict environmental regulations, contractors must consider the disposal of materials from the grinding process, and it is important to have a plan in place before the job is started. If the surface being removed is contaminated by oil, chemicals, radiation or other hazardous materials, one must dispose of them according to government regulations.

DON’T:

FORGET TO MAINTAIN

THE MACHINE

Low-speed surface grinders are fairly simple machines. Besides regular engine maintenance on gaspowered units, there aren’t many components to service. But because the concrete dust grinders produce

is extremely abrasive, there are several important lubrication needs.

One of the most common maintenance items that is overlooked is to lubricate the transmission bearings. The problem exists because maintenance personnel typically do not invest the time to remove excess concrete dust accumulations around the bearings after use. Eventually, the grease fittings become hidden from sight, and dust continues to contaminate the bearings. This results in total bearing failure, which may consequently damage expensive transmission components. To combat this problem, some manufacturers have incorporated a remote lubrication system designed to simplify maintenance, but even this cannot prevent all abuse. Therefore, make sure the bearings are greased according to the maintenance schedule.

Next, keep an eye on the attachments. These are key to operational success, so make sure they wear evenly and replace them as the contact surface approaches the attachment discs. Although the service life of attachments varies based on the application and use, have an idea of how long each specific one might last. For instance, one could estimate that a set silicon carbide grinding stones may last approximately 5,000 square feet, while a diamond system could cover up to 50,000 square feet before replacement is needed.

TRIED AND TRUE Although new machines have taken much of the recent attention, low-speed surface grinders will continue to stand the test of time.

Thanks to their versatility, they can be a seen as a profitable and productive inventory item, rather than an endangered species. And by understanding the simple tips listed above, more contractors can realize the full potential of these machines.

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CONCRETE TECHNOLOGY

By Joe Nasvik

Robotic

Total Station Update

How manufacturer’s are making them more contractor friendly.

T

otal robotic stations were once regarded as tools for surveyors only. But that changed several years ago when contractors began to see the value of using them to do their own layout work. Concrete Foundations Association (CFA) member contractors were among the first construction groups to invest in the technology—laying out footings and foundations and reducing reliance on surveyors.

Trimble, Leica, Topcon, and Sokkia are the primary manufacturers of the instruments but more recently Leica has focused on the construction industry by developing hardware and software which is more understandable to contractors. Here’s an update on the technology and the reasons why you should consider using it.

The instrument for a total robotic station is un-manned. Bluetooth and laser technology allows it to communicate with the target and tablet computer located on the rod.

Photo Credit: Atlantic Concrete

HOW IT EVOLVED With the invention of theodolites teams of surveyors could accurately measure both horizontal and vertical angles. This along with tape measurements allowed them to lay out points. The invention of total stations combined the ability of theodolites with electronic distance meters (EDM) using infrared technology to eliminate the need for tape measures, making layout faster and more accurate (they now use lasers to measure distance).

But it still required two people, one at the instrument and one at the “rod” or “stick.” Before going to a jobsite they determined what the control points were for a project relative to

multiple known points such as property stake markers. Even though plans are two dimensional (X and Y), surveyors could accurately locate points on sloped or uneven land.

The introduction of robotic total stations brought several improvements, starting with the equipment. It consisted of the instrument, which included a radio and a laser beam. Several changes were included to the rod or “target.”

A series of prisms were added at

the top of the rod to reflect light in 360-degrees, a small touch screen monitor was attached along with a radio and battery pack. A small computer or “data collector” device was also attached to the rod.

At the office, before going to a jobsite, workers downloaded computer assisted drawings (CAD) into their data collectors to provide direction for point location. For the first time only one person was needed to do the work.

On the jobsite the instrument could be

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set up anywhere. By shooting known points on the plans the instrument could automatically locate itself. The laser at the instrument locates the prism at the top of the rod and the instrument then follows it wherever it moves. The radio on the instrument communicates with the data collector and instructs the worker where to move to locate a desired point.

Problems with this system included interference with radio frequencies by other radios and light reflections from local sources causing the instrument to lose track of the target.

MAKING CONTRACTOR FRIENDLY CHANGES Scott Carter, owner of Robotic Surveying Solutions, Kaysville, Utah, both sells and trains contractors in the use of robotic total stations. He recently investigated several product leaders and decided to represent Leica because he thinks they have done the most to serve the contractor market.

Rapid Set

®

Working from the rod, workers can view the layout plan on the tablet mounted on the rod to locate points. The 360-degree prism at the top allows the instrument to follow the rod wherever it goes.

Photo Credit: Herbert Construction Company

Here are some of the improvements.

Bluetooth. Bluetooth communication has replaced the use of radio signals between the instrument and the target. Scott says that long range Bluetooth communication is much more dependable at ranges up to 1,500 feet—ideal for contractors but not for surveyors because they often plot longer distances between the instrument and target. The problem for radios is that too many things can interfere with the signal and they require battery packs which must be lugged around with the target.

LOCKING INTO THE PRISM Keith Lantz, the Western Regional Manager for Leica Geosystems, Littleton, Colorado, says the development of advanced target recognition (ATR) enables instruments to lock on to target prisms much better.

It’s rare for an instrument to lose targets now.

Speed of tracking is also greatly improved and such things as reflections from car headlights and other disturbances are no longer issues.

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www.forconstructionpros.com/concrete | August/September 2016 | Concrete Contractor 45

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CONCRETE TECHNOLOGY SWITCHING TO TABLETS Carter says that tablets with up to 11-inch touch screens have tiny screen data collectors, making them much easier to read and work with.

They are rugged, water resistant, and are attached to the rod.

SOFTWARE Workers can accurately locate points regardless of site conditions such as in excavations, sloped areas, or in mud. The instrument can be located at a safe distance from construction traffic and automatically compensate. The worker shown here is carrying the rod with a computer tablet mounted on it.

Photo Credit: MG Construction

Software programs give people in the field much more flexibility. It’s much easier to load CAD files and also make changes to drawings in the field.

Language. When contractors first started using robotic total stations they had to learn surveyor terms. For example, surveyors are used to working with coordinates while contractors live in the world of dimensions. So software

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tablets use terms and concepts that contractors are familiar with. This change also makes it easier for contractors to learn how to use them.

Larger tablet screen graphics have improved too, making it easier for operators to visualize their work.

Scott says in the past data collectors indicated which way you should move to locate a point. Now you can see a CAD drawing of what you are laying out on the tablet with the location of the target in relation to the point on the drawing you are trying to locate.

FOUNDATION LAYOUT Doug Herbert, President of Herbert Construction Company, Marietta, Georgia, says they install both commercial and residential foundations. They bought their first robotic total station in the mid-1990’s during a time when they were also installing trench foundations. “Layout in a trench is difficult and when my

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46 Concrete Contractor | August/September 2016 | www.forconstructionpros.com/concrete

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dad found out about robotic total station technology we invested in one and never looked back,” he says.

Herbert is sure they were the first foundation contractor to buy one.

When they first presented the idea to Concrete Foundations Association (CFA) members at one of their conferences he remembers some members thought the units were too expensive.

But others saw the advantages and started to buy them. Today approximately 90 percent of CFA members own them but many contractors still pull two tape measures to locate points, even though long distances and slopes decrease accuracy.

Given the fact that only one person is needed to do layout work with robotic total stations Herbert says his companies pay-back time was only two years.

Herbert Construction uses Carter’s service to train new employees, help CAD specialists learn how to use

Workers can easily locate anchor bolts within accuracies of 1/8 of an inch.

Photo Credit: Atlantic Concrete

more effective software for transferring files into the instruments, and to provide updates when new technology comes out. They lay out all their projects with their instrument—their footing foreman waits for their layout specialist to locate the points he needs rather than attempt layout on his own.

Foundations often involve multiple elevations now, making

layout more difficult than in the past. But Herbert says using robotic total stations to lay out X, Y, and Z (height) axis makes the task easy.

His message to other contractors is that this technology pays for itself in accuracy, speed of layout, and reduced manpower.

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CONCRETE TECHNOLOGY WORKING WITH TILT-UP Tilt-up contractors use robotic total stations for some of the same reasons as foundation contractors; to establish points for footings and foundations. But accuracy for doing panel layout is very important and these instruments also save time compared to locating panel points with tape measures. Glen Doncaster, President of Citadel Contractors, Inc., Apex, North Carolina, says they bought their first total station in 1997 and began doing their own layout work. He thinks their in-house work is more accurate and scheduling is easier.

Craig J. Olson, Project Engineer for C.E. Doyle LLC, a design-build contractor located in Campbellsport, Wisconsin, decided to stop setting up batter boards and pulling string lines in 2008. They bought a robotic total station and got into the practice of attaching prisms to walls and other places for the length of their project, allowing faster checking and greater accuracy.

meet the spec can be reworked while there is still time,” he says.

To summarize, here are some of the improvements to robotic total stations technology: • Companies like Leica write language in the voice of contractors making them easier and more understandable to use.

• Graphics on larger tablet screens are easier to understand and work with.

• Tracking mechanisms in the instrument lock onto the target better.

• Software for downloading drawings into the tablets used by robotic stations is greatly improved.

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NEWER TECHNOLOGY The difference between robotic total stations and 3D laser scanners is that the former is used to establish a small number of points whereas the latter captures a million or more points per second. When a new project is started project surveyors often use 3D laser scanners to scan property and download the information into CAD or BIM software to facilitate the development of working drawings and control point locations. Finished plans are then downloaded into robotic total station tablets to locate the control points. But Lantz says his company recently introduced a multi-station instrument that provides both functions. It can scan approximately 10,000 points per second, considerably slower than a 3D laser scanner but fast enough to meet the needs of contractors. “With these instruments you can also ‘wet-scan’ a freshly placed concrete floor slab to determine if it meets specified flatness requirements. Locations that don’t

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www.forconstructionpros.com/concrete | August/September 2016 | Concrete Contractor 49

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FOUNDATION Q&A

By James R. Baty II

Why Wait to Form

Walls on

FOOTINGS?

The Concrete Foundations Association explains the rationale behind the speed available to the construction of residential concrete foundations and why footings are not susceptible to damage if the contractor continues the forming process on day two.

Contractors regularly look at the basic U.S. residential concrete foundation as being a three-day process. Excavation, footing forming and concrete placement on day on; wall forming and concrete placement on day two; and form stripping, clean-up and waterproofing on day three. This facilitates a quicker turn for the foundation ready for the builder to begin the above-grade work.

Q

uestion: During the construction of a residential foundation, the inspector passed our footings and then informed us the next day we were not to start setting panels on the one-day old footings until the concrete had reached seven days. The restriction was then changed to three days when we challenged based on standard industry practice. However, this was still a length of time we could afford in our work schedule. The footings were poured and inspected on Monday. On Tuesday we were informed that the footings passed inspection but we were to wait, after our crews had already left to travel to the jobsite. By the time we got word and connected with the

Contractors regularly look at the basic U.S. residential concrete foundation as being a three-day process.

Excavation, footing forming and concrete placement on day one; wall forming and concrete placement on day two; and form stripping, clean-up and waterproofing on day three.

Photo Credit: Concrete Foundations Association

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crew, the wall set was practically completed. The inspector then informed us that we could not pour the wall that day and that we needed to wait for seven (and eventually three days).

Despite our plea and our statements of standard industry practice, we had to tear down all of the forms that were set and move on to another jobsite. Moving to the next jobsite in a different part of the region, it is interesting to note that the inspector for that area told us there is no state inspection criteria for a poured foundation and he did not need to see anything until the wall was waterproofed and ready for a house to be built on it. This area defers to IBC1 and IRC2 for guidelines. I have thoroughly researched those and found no time restrictions regarding the footing cure time prior to wall placement. Can you advise on the minimum allowable footing cure time prior to wall placement?

A

NSWER: This is not a very common situation encountered in the marketplace today, although it is systemic to the stress many code departments are under and the prescription of information from one method of construction or situation applied as a blanket provision. The steps to help inform the inspector were the right steps to be taking, unfortunately very few situational disagreements can be won on the basis of time, money or labor.

So what can be done to prove or substantiate the claims of this situation and ensure the adequate performance of the concrete?

As a contractor, understanding of the applicable codes is the first important step in fostering a successful and productive conversation. This

is one of the reasons why the ACI/CFA Residential Foundation Technician Certification exists, to assure and certify individuals to a level of knowledge in the use of the major industry references. The contractor in this situation identified the IBC and the IRC as applicable or adopted by their jurisdictions. Although the project is residential in scope and conforming to the requirements of the IRC, it is also important to know the stance of the IBC in the event that it is a cross-interpretation or a misapplication of one provision to another.

The International Residential Code (IRC), when adopted by any jurisdiction provides the minimum design requirements for life safety and structural stability. The IRC provides very little guidance at all on means and methods, which become the basis for determining impact to construction timeline and schedule. There is no guidance for the working strength or the timing for strength development in concrete footings in the IRC. What is provided is a minimum design strength for the concrete, which is only a direction of the minimum 28-day design strength with no bearing on the working strength during the construction schedule. There is no correlation between final design strength even at 28-days and the loads determined to be applied. It is rare that a residential project (or commercial for that matter) is ever completed in a cycle less than 28-days that would adversely affect the capacity of the footing for interim working loads.

In terms of requirements for footings, the IRC does provide they are to be designed and constructed according to the provisions in its own section R403 or in accordance with ACI 3323.

Without any indication in the footing section, review of the foundation wall criteria is important. The IRC provides guidance for foundation walls to be designed and constructed according to R404 or in accordance with one of three other references, ACI 332 again being one of those. Throughout section R404, issues of the mechanical design are addressed along with the

requirements for minimum strength of concrete, maximum aggregate sizing and the timing of the mix. There are no provisions for the length of curing nor the timing of load to a foundation wall or timing of necessary support for the placement of a foundation wall.

This is where it is then important to know what is required from reference standards, such as that of ACI 332. This document provides a concrete-specific focus with far greater detail to both footings and foundation walls than the IRC. This is a technically exhaustive document for an application such as residential foundations, intended to cover the completeness of the method of construction. In this document (332-14), the following is found in section R6.3:

...understanding of the applicable codes is the first step in fostering a successful and productive conversations.

FORM REMOVAL Forms shall be removed in a manner that does not impair safety and serviceability of the structure.

Concrete exposed by form removal shall have sufficient strength not to be damaged by the removal operation.

The extent of direction to the contractor for proceeding to the next phase of the project is limited to when the concrete will not be damaged by the next operation. No minimum strength threshold is given. It simply makes sure that the concrete element won’t fall down, apart or otherwise be damaged by being too green to move on to the next process.

Next, curing is described by ACI 332; a topic not addressed by the IRC other than by reference or deference to ACI 332, where it states in section R6.5:

CURING After placement, concrete shall be protected to maintain proper moisture and temperature. Protection shall

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FOUNDATION Q&A ensure that excessive water evaporation does not impair required strength or serviceability of the element.

The section then refers to specifics of protection during times of cold weather and hot weather, both extremes and neither placing any limitations on the concrete other than meeting a minimum strength of 500 psi in the winter, when delays in strength gain are most common due to temperatures below the freezing point of concrete. These sections occur in the materials part of the document.

In neither the footings chapter nor the foundation walls chapter, are there conditions limiting the timing for the next step or the length of time that curing or protection needs to be in place in order to move to the next stage. This is due to the significance of strength gain in normal concrete applications and the very low loads applied to the concrete during construction.

So without any direct reference

ASSUMPTIONS

to an adopted code provision or found in a reference standard provisioned to the adopted code, the conversation can be more productive if they physical science of the condition is looked at. A quick example of a typical calculation for the footing condition demonstrates the insignificance of the concern for concrete strength during the construction period.

Soil capacity (2,000 lbs./sq.ft.) more common in residential developments, minimum footing concrete design strength (2,500 lbs./sq.in.) and a capacity or predicted maturity after one day in 70-degree Fahrenheit temperatures of 1,500 lbs./sq.in. (see CFA Cold Weather Research4) and a common concrete weight of 150 lbs./cu.ft.

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Maturity curve generated during the Cold Weather Research for Foundation Walls by the Concrete Foundations Association (2004) showing a plain, fivesack concrete mix stored at 50-degrees Fahrenheit showing 1,500 psi in just a day and a half.

Photo Credit: Concrete Foundations Association

Foundation wall weight 9-ft tall x 8-in. concrete foundation wall sitting on a footing weighs or applies a load to the footing of 9 ft. x 8 in./12 in/ft.. x 150 pcf = 900 lbs./lin.ft.

Load capacity of footing Foundation wall thickness of 8 in. x 12 in. length of wall x 1,500 psi = 144,000 lbs./sq.in. or 1,000 lbs./ lin.ft. at assumed one-day strength.

Therefore, assuming an minimum strength gain for the concrete in just 24 hours, the footing has already enough capacity at its surface for the applied load of the wall.

Capacity of the grade Supporting the load applied by the wall to the continuous footing, the soil capacity would be the next check.

A 16-in. wide footing gives adequate space for forming the wall (ACI 332 requires 2-in. min. footing width per side + wall thickness), so 16 in. / 12 in./ft. x 2,000 psf = 2,666.7 plf, more than two-times the applied load of the combined wall and footing weight.

It is for these reasons why the timing of progress on the footing and even the foundation wall construction is not an issue. It is also for these reasons that even construction guidance documents such as ACI 332R-065 does not address the timing issue between footing and wall construction.

The CFA documents a standard or basic foundation construction process of three-days from excavation to the completion of the form removal process on the walls. This would not be possible where there any doubt in

the capacity of the concrete footing to sustain the loads of the foundation wall it supports.

Ed. Note: Jim Baty is the Executive Director of the CFA and can be reached at (866) 232-9255 or by email at jbaty@cfawalls.org.

References: 1. 2012 International Building Code by the International Code Council, Inc., www. iccsafe.org 2. 2 012 International Residential Code ® For One- and Two-Family Dwellings published by the International Code Council, Inc., www. iccsafe.org 3. Residential Code Requirements for Structural Concrete (ACI 332-14) and Commentary published by the American Concrete Institute, www.concrete.org 4. C asting Residential Foundation Walls in Cold Weather – CFA Cold Weather Research Project – 2004 Report published by the Concrete Foundations Association, www. cfawalls.org 5. Guide to Residential Concrete (ACI 332R06) published by the American Concrete Institute, www.concrete.org

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Idea File The Next Generation Of Decorative Concrete Flooring...

Aurora Epoxy Dust is a new type of epoxy floor system unlike anything the industry has seen before. A high definition 3D image is achieved by blending metallic pigment with clear epoxy binder that results in seamless sheer elegance. Aurora Epoxy Dust reflects light rather than absorbing it, producing a floor that has more depth and dimension than is obtainable with concrete staining.

Our system provides the ultimate uniform surfacing solution. Professional contractors recognize the true value of a fast application process that greatly decreases down time, potential for non-uniformity and other stress factors associated with concrete stains and overlays. To learn more about Aurora Epoxy Dust visit our website at www.mckinnonmaterials.com or contact us at 1-866-622-7031.

LAVINA 32M-X is a self-propelled (NOT remotecontrolled) floor grinder with a large 32-inch footprint, new chain-driven forced planetary drive with SIX 9-inch heads, and a heavy duty 25 hp motor (3phase, 380/480 Volt, 35 Amp). It offers high productivity rates and is an ideal solution for large commercial projects! It can be used for all grinding and polishing applications, adhesives and coating removal, surface repair and flattening of concrete, terrazzo, etc. It easily fits through all standard doorways. The simple control panel (no remote devices) makes it easy to use, and the self-propelled drive means there is no impact on the operator during grinding.

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54 Concrete Contractor | August/September 2016 | www.forconstructionpros.com/concrete

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Having Productive efficient vacuums connected to equipment, collecting the dust when working is key! Not only is the vacuums air flow (CFM) and water lift important, but the type of filter is crucial to collecting the smallest most harmful partials from the air. All vacuums should be outfitted with HEPA filters rated at 99.99 at .3 microns that are certified and individually tested. The proper vacuum with these features save time and money.

When selecting a vacuum, the contractor needs to look for the following features: • High quality HEPA filters, that are tested and certified.

• Multi levels of filtration, cyclonic, pre filters and HEPA filter.

• Contained filter cleaning with JET Pulse, so as not to allow dust to escape when cleaning.

• Control of dust when changing bags with drop down Longopac system.

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Idea File

The Husqvarna PG 820 RC remote control planetary grinder offers very high productivity, powerful performance, and outstanding ergonomics.

The remote control is key on this machine. It enables the operator to move around the jobsite, correcting hosing, moving the dust collector, inspecting the floor, and preparing the next set of tools. The remote control can also optimize the grinding parameters to assure quality for a specific application, enabling consistent results even

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56 Concrete Contractor | August/September 2016 | www.forconstructionpros.com/concrete

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INDEX ADVERTISER................. PAGE

Kut-Rite Manufacturing.................. 35, 56 Larsen Products Corporation............... 23

Advance Metalworking Company............................................... 53 BackSaver.............................................. 36 Bloom Manufacturing Inc..................... 22 Briggs & Stratton Corp......................... 15 CMS Pervious........................................ 53 Collomix USA........................................ 43 Concrete Polishing & Staining Conference and Expo.................... 39, 48 Concrete Polishing Association.............46 CTS Rapid Set Cement Mfg Co................................................... 45 EDCO Equipment Development Co.................................. 46 Ermator USA...................................19, 55 EZ Screed Tools.................................... 22 Fascut Industries................................... 13 GelMAXX............................................... 38 Husqvarna Construction Products.............................................. 2, 41, 56 Inspection Instruments......................... 38

Laticrete................................................. 37 Line Dragon, LLC.................................. 33 LM Scofield Company.......................... 47 Mapei Corporation USA...................... 60 McKinnon Materials, Inc........... 30-31, 54 MK Diamond Products, Inc................... 9 Niagara Machine Inc............................ 17 Polished Concrete University............... 52 Runyon Surface Prep Rental & Supply.................................................... 52 Simpson Strong-Tie Co., Inc................. 5 Solomon Colors.................................... 49 Substrate Technology Inc..................... 29 Superabrasive Inc........................... 27, 54 Terrco Inc......................................... 18, 57 Trimaco.................................................... 7 Trinic....................................................... 42 Wacker Neuson Corp......................11, 55 Wagner Meters..................................... 13 World of Concrete................................ 59

For over 85 years Terrco Inc has produced reliable, low maintenance grinding/polishing equipment. Capable of anything from demolition work, surface prep and all the way to a high polish.

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THE LAST PLACEMENT: BACK TO BASICS

Tips for Maintaining Your

POWER TROWEL

Conducting routine maintenance on your power trowel will ensure optimal performance on each project.

I

t’s always best to check with your trowel manufacturer's maintenance guidelines to determine the best maintenance intervals for your equipment, however, below are a few tips to be mindful of when maintaining your power trowel.

DAILY: One of the most important daily maintenance items you can do to keep your trowel in tip-top shape is to instruct customers to power wash it at the end of each use. This will keep it looking professional and free from excess grease or other debris that might gum up moving parts. And your customers won't have to worry about dried concrete dropping onto their floor. For when the machine is back in your shop, there are cleaning solutions designed especially for removing dried-on concrete as well as products you can apply to your trowel to make it easier to clean at the end of each rental.

Greasing and maintenance checks can be easily performed after each use. This will ensure your trowel is ready to go for the next customer.

The concrete slab is a tough environment for your trowel engine, make sure you're taking a look at the engine components every day. One of the most common problems is not checking the air filters. Concrete dust will choke the engine the machine will not operate at the optimal power level.

Examine the air filter every day for potential clogging. With a liquid-cooled engine you'll want to check your coolant level daily. On all engines you should check the oil level and for oil leaks.

Before turning on the machine,

the operator should perform a visual inspection making sure the bolts that attach to the blades are tight and the safety guards are in place.

WEEKLY: Weekly inspections emphasize a closer look at your trowel's bottom end. A bent spider arm - the part of the trowel that holds the blades or pans - can result in a swirling pattern or waviness to the finish.

An experienced operator can recognize these problems during operation, but noticing these problems during a job can often be too late to fix them in time to save the slab without re-work.

Most manufactures offer spider assemblies with adjustable arms. This allows you to compensate for a bent arm and ensure your blades are all working on the same plane.

Examine the drive belt weekly.

Rubber drive belts will disintegrate with heat. Make sure your trowel's belt is in good condition, and change it when you begin to notice wear.

MONTHLY: Monthly maintenance items take a step beyond your daily engine maintenance checks. In other words, while you're checking oil levels and air filters or coolant daily, you should plan on monthly replacement or cleaning. Be sure to examine your engine manufacturer's recommendations to determine the best engine maintenance schedule. Not all engines are the same - air-cooled engines will generally need more frequent oil changes than liquid-cooled engines.

Another engine feature designed for easy maintenance is an oil alert system, which notifies the operator if the engine oil level drops below a safe operating level.

Before changing the oil, it’s always best to run the engine for two or three minutes to warm it up before changing the oil. Warm oil drains better and faster, plus running it before changing the oil will help remove more of the debris that is suspended in the oil.

Check your engine manufacturer's recommendations for oil type and weight.

When it comes to buying coolant for your engine, be sure to read the labels. With the number of coolant blends available on the market, you might think you're buying a blend when you're actually buying a straight coolant. And never think straight water is going to cut it for a hard-working trowel.

ANNUAL: In addition to routine maintenance, there are a few annual checks you'll want to add to your maintenance schedule. Again, based on your manufacturer's suggestion for annual use, which is typically considered 300 to 500 hours of use, these are items you might end up doing once a year or a few times a year.

Change your gear box oil. There's a lot of friction in these gear boxes and a little bit of wear on those gears. You will want to remove the metal out of the box or it's going to accelerate wear inside the gear box.

You should also pull out your blade arms and ensure proper adjustment, plan on replacing belt drives at least once a year, and closely examine your trowel's blade-tilt mechanism. With walk-behind trowels, annual maintenance on the throttle cable is critical. Use a synthetic grease in the throttle cable, which tends not to attract water as much as a petroleum-based oil can.

58 Concrete Contractor | August/September 2016 | www.forconstructionpros.com/concrete

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JANUARY 17-20, 2017 SEMINARS: JANUARY 16-20 LAS VEGAS CONVENTION CENTER LAS VEGAS, NV, USA A selected participant in the International Buyer Program

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MAPEI takes it to the next level with Mapefloor ™ Parking Deck Systems For standard and heavy pedestrian/vehicular traffic

UV-resistant polyurethane topcoat

Mapefloor Finish 450 Polyurethane intermediate membrane + broadcast with 16/30 mesh sand

Mapefloor Finish 415 NA High-flexibility polyurethane basecoat

Mapefloor PU 400 LV

Epoxy primer

Primer SN ™

Concrete

Mapefloor parking deck systems provide surfaces with the following: • High flexibility with good crack-bridging capacity • High resistance to wear and abrasion for long-lasting performance • Low-odor and VOC-compliant • Excellent resistance to chemical agents, including diluted acids, bases, oil, fuel and salts • Highly attractive wearing surface Ask your local sales representative about our Mapefloor parking deck systems or visit www.mapei.com.

Keyword: MAPEI Americas

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8/26/16 10:37 AM