Concrete Contractor December 2014

The Secrets to Specifying Bonded Abrasive Polished Concrete, Page 42 December 2014

Reorganized ACI 318-14 Provides a Modern Code Platform Page 36

Charging Batteries by Induction Page 32

Spotlight on

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Contents December | Issue 7, Volume 14

Spotlight on DECORATIVE CONCRETE

Cover Story 18 Conservatory

Green Embraces Community

Once a bustling airport, the Stapleton Denver redevelopment now flourishes with new life as mixed-use developments embrace the suburban location and lifestyle.

24

24 Chef John’s

This 16 year old restaurant floor looks as good as the day it was installed.

28 Decorative Concrete

18

Product Round-up

Features

Departments

34 Fastening System Earns

8 The Three C’s Drive Success

Coordination, collaboration, and cooperation between the general contractor and sub-contractors would determine whether or not the project would be completed on time.

14 Concrete Contributes to

Student Life Experience

As a central place for a community building at North Carolina State University, officials had a vision for the Talley StudentUnion — create a hub for quality, student life experiences.

Its Stripes with Military Facility Installation

A new fastening system allowed crews to complete the job 70 percent faster than originally anticipated.

4 Editor’s Letter 40 Foundation Q&A

By Jim Baty

36 Reorganized ACI 318-14

Provides a Modern Code Platform

New construction chapter will help contractors execute structural concrete assignments as designed.

42 The Secrets to Specifying

Bonded Abrasive Polished Concrete for New Construction

32 Charging Batteries

Why polished concrete installations go wrong and why specifications by themselves aren’t enough for success.

by Induction

Will this spark another revolution in the corrdless tool industry?

14

28

34

42

www.forconstructionpros.com/concrete | December 2014 | Concrete Contractor

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Editor’s Letter

Get Involved, Reap the Benefits

I

joined Concrete Contractor in February. As I look back to the last 10 months, my experience in this industry has been a remarkable education.

As you look to the end of the year, and prepare for what’s to come in 2015, I’d encourage you to get involved in your industry. Over the last several months, I attended the annual Concrete Foundation Association convention, the Fall American Society of Concrete Contractors Conference; and the American Concrete Institute - Fall Conference. In all instances, I left these events with knowledge I didn’t have before and a bevy of new contacts to help me in my day-to-day job as an editor of an industry publication.

These industry associations help make concrete the shining star of the construction industry. They are also tasked with recruiting new members and encouraging current members to become more involved with the activities of these organizations. If you’re not a member of an industry association, I encourage you to take the time to learn about them and determine which one would be the ideal fit for you. Joining any one or all of these groups will yield benefits beyond your work in the field. You’ll have access to members just like youself to share your ideas and goals. This is also a great opportunity for you to develop a positive, business relationship with the vendors of the products you use.

Advisory Board

Published by AC Business Media Inc.

Editor

Ryan Olson,

ROlson@ ACBusinessMedia.com (800) 538-5544 Facebook.com/ ConcreteContractor Follow us @ Concreteinsider Search: Concrete Polishing

Industry associations like these have a common goal – which is to continue to add value to the concrete community through research, establishing standards and helping you perform your job.

Here are some helpful links: • Concrete Foundation Association: www.cfawalls.org • American Society of Concrete Contractors: www.ascconline.org • American Concrete Institute: www.concrete.org • Concrete Polishing Association of America: www.concretepolishingassociation.com As you page through this, the December issue of Concrete Contractor, we put a Spotlight on Decorative Concrete beginning on page 19.

You may notice that Polishing Contractor is no longer a part of the “flip-cover”. We have decided to pull Polishing Contractor into the magazine as its own special section. Don’t worry, we’re not moving away from our coverage on polished concrete, we remain committed to covering this growing and exciting segment of the industry. Turn to page 42 to read this month’s entry – “The Secrets to Specifying Bonded Abrasive Polished Concrete for New Construction.”

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.

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

Joe Reardon SASE Orlando, Fla.

4 Concrete Contractor | December 2014 | www.forconstructionpros.com/concrete

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Flatwork/Slab

The Three C’s Drive Success

A manufacturer needed to fast track the construction of a new manufacturing facility in less than 10 months. Coordination, collaboration, and cooperation between the general contractor and sub-contractors would determine whether or not the project would be completed on time.

By Ryan Olson

S

itting on a 75-acre site in Houston, Texas, OMK, a supplier of casing and line pipes to the U.S. market has a new facility to call home. The mill is designed to produce greater than 200,000 tons per year of oil and gas pipes.

Mission Constructors, Inc., the General Contractor, selected Houston-based TAS Commercial Concrete as the concrete contractor who would place the foundation footings, auger piles and construct a concrete slab strong enough to withstand a manufacturing environment.

Since 1980, TAS has grown to be one of the premier concrete contractors in the Houston and Dallas, Texas region. The company has invested more than $25 million in their fleet which includes pump trucks, laser screeds, dozers, and backhoes. Today, TAS is comprised of over 1,200 employees and is known for their attention to detail and quality work.

Seven months to complete the project

“Jay Lindley, of Mission Constructors, came to us with a very large request,” says Tim Manherz, Vice President of Operations at TAS. “Can we finish this facility if we start on May 1, (2012) so OMK can begin manufacturing pipe by the end of the year?”

In order to accommodate the client’s request, it was paramount for Mission, TAS, and other trades

Mission Constructors asked TAS to help build a manufacturing facility within a seven month timeframe. Photo Credit: TAS

on the job to meet and determine a schedule agreeable to all parties. Big jobs like this need a lot of coordination and not your ordinary level of coordination, but at a high-level. As if completing the project in a seven month time period wasn’t challenging enough, Manherz says the project was also a design-build project.

“When we started the job, we barely had any of the foundation drawings to begin our work,” he says. “There were a lot of unknowns,

most of which we wouldn’t know until just before we would begin working on a specific section.”

While this was a unique project for TAS, it wasn’t completely unfamiliar territory. Two years ago, TAS completed a similar job in the area. “We were lucky enough to pick-up that high-demand, unique, difficult project and the people we built it with gave us the knowledge on how to work with other trades on the jobsite.”

8 Concrete Contractor | December 2014 | www.forconstructionpros.com/concrete

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Flatwork/Slab

The interior slab of the facility was constructed in sections which were 12 inches thick. Photo Credit: TAS

Manherz says the experience from that job allowed TAS to bring their knowledge to the table and help everyone on the jobsite understand how the project would come together.

Foundation work

TAS was responsible for constructing two foundations for the OMK project. Auger cast piles were to be constructed for areas of the building to house steel coil and heavier equipment. The building itself was to be a pre-engineered metal building and sits on bell bottom piers.

The first of several challenges included building a slitter pit that was 30 feet below finish grade.

With all the brainstorming between the trades (primarily coordination with the steel erector, the excavator, and the electrician), a plan was put into place to allow TAS to initially start the 30 foot deep structure and get that waterproofed and back-filled as soon as possible.

“We started with the slitter foundation above ground, and had multiple elevations, anchor bolt pockets, anchor bolts, and circular forms,” says Manherz. “With the use of a Unistrut, we were able to incorporate the wide flange beams, which weighed between 400- to

1,000-pounds, into our pours with excellent accuracy.”

He adds the coordination between the trades, especially TAS and the electrician was equally important in keeping the job on track.

“We had to get the exterior forms up and the lower mat of steel placed, then the electrician had to get their conduit on top of our lower mat into specific locations for the equipment to receive power.”

Adding to the obstacles, the electrician was receiving information sometimes days before and, at times, hours before the conduit was to be installed. This was largely due to the engineering drawings still being designed.

Because of changing weather patterns and constant exposure to weather conditions, it was imperative that once the pit was complete, the foundation work for the pre-fabricated steel structure would begin.

The foundation consisted of 90-foot auger cast piles, and according to John Joyce, Senior Project Manager, the auger cast pile design was an ongoing issue for the same reason as the construction of the slitter — where should the auger piles be located? “Most of the piles were within a rectangular area with

an unusually thick concrete slab of 12 inches. This area would be where the coils of steel would sit.”

“We started with drilling the piles for the interior pier caps first and then moved to the exterior grade beam of the building,” Manherz explains. “Because of the accelerated schedule, we had to meet with the engineer and create a construction joint for the slab on grade so we could place the slab monolithically on the exterior grade beam in order to receive the steel for the structure.”

Starting at this point for the foundation was critical in order for the steel erectors to begin their building process while the foundation had time to cure.

“We continued to move east to west taking care of the foundations and staying ahead of the steel erectors, about 10 column lines or so,” Manherz says. “They followed us by erecting the building and putting on the roof and drying the building which allowed us to work in conditions that were not affected by the weather.”

Creating the slab on grade

Three hundred and sixty five additional auger piles were also needed, to be placed on an eight foot grid in both directions underneath the receiving area slab to house the rolled steel that was going to be railed in for the manufacturing of piping.

Coordination between TAS and the mechanical contractors was critical to the success of pouring the slab. And according to Joyce, the pour was never really completed at one time but was strategic in nature.

The interior slab of the facility was constructed in sections which were 12 inches thick.

“When it was determined an area would be the location for a piece of equipment, we could go in and pour the slab around that specific area.

For example, we could pour up to column line 28 and then we’d have to stop until we knew where the next piece of equipment would go.”

In addition to the foundation

10 Concrete Contractor | December 2014 | www.forconstructionpros.com/concrete

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Flatwork/Slab and flatwork, Joyce says, “The floor we built is laced with trenches to catch the fluids that are involved in the manufacturing process. There is a maze of graded trenches in the floor — under the equipment and between the equipment. What was always part and parcel to the project, was how quickly can we get the floor done, based on when we know a piece of equipment will arrive on-site.”

“It made it extremely hard for the engineers to coordinate between all of the equipment manufacturers to receive their equipment information, design the foundations, and then get those finished drawings back to the steel manufacturers to expedite those items quickly,” Manherz says.

With the purchasing process of equipment for the facility becoming an on-going operation, Joyce says, “We were always being updated on the engineering drawings, the plans, the exact openings, beam locations, embedded beams; everything was unique to an individual piece of equipment. It was always down to the wire.”

Equipment challenges

Continuing to challenge the crew at TAS, OMK was purchasing equipment for the facility from multiple sources — USA, Canada, Italy, and Japan. Many measurements were in metric, requiring the crew to make any necessary conversions in order to construct the proper dimensions in the area where concrete was to be poured.

The floor within the facility was built with trenches to catch the fluids associated with the manufacturing process.

Photo Credit: TAS

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12 Concrete Contractor | December 2014 | www.forconstructionpros.com/concrete

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“I’m certain, if we had to wait even two days for some decisions, it would have cost us. This project has been a demonstration of the importance of working together with other contractors. Everybody wants to get the job done, but getting there is dependent on how well your team can work with others.”

“The biggest accomplishment on this job was the fact we had cooperation up and down the line,” Joyce says.

“From the owner to the design team; the contractor, the suppliers — without that, the whole process goes away.

We had to work together, otherwise we would have never finished.”

The slitter pit foundation was above ground, featuring multiple elevations, anchor bolt pockets and circular forms.

Photo Credit: TAS

had it not been for the relationships they formed.

“We had a relationship with Mission before we took on this job,” Manherz says. “In fact, one of the vice presidents of another company we previously worked with now works with Mission and that helped strengthen our relationship with the company.”

Manherz says TAS is a preferred concrete contractor for Mission. “And that’s because of our relationship with them, especially so after this project.”

Precise scheduling between the general contractor, TAS, the electrician, the plumber, and the steel manufacturer supplying the metal building walls was critical. “This was going to take timing and coordination in order to get the fabricated metal building up as quick as possible,” Manherz says.

All parties were able to work together to come up with a “schedule” which allowed TAS to work east to west with the foundation. The steel sub-contractor followed behind, until the roof was put in place. Once the building was enclosed, the crews at TAS were able to follow the steel subcontractor and continue their work.

Additionally, OMK, the owner of the building, had a representative on site that had the authority to make decisions without much delay.

“Having the OMK rep on site was extremely helpful,” Manherz says. www.forconstructionpros.com/concrete | December 2014 | Concrete Contractor

CONC1214_08-13_Flatwork.indd 13

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Foundation/ Walls

Concrete Contributes to

Student Life Experience As a central place for a community building at North Carolina State University, officials had a vision for the Talley Student Union — create a hub for quality, student life experiences.

Scheduled to be completed in 2015, the student union will be a place committed to student success.

By Ryan Olson Pictured here is an overhead view of what was called Area A - The Mohawk at North Carolina State University. Photo Credit: Briegan Concrete Constructors

PROJECT PROFILE: • 7,120 cu. yd. of concrete poured

• 530.54 tons of rebar • 20,000 lbs. of post-tension reinforcing

• 63,571 sq. ft. slab on grade • 28,551 sq. ft. elevated structural post tension slabs

• 2,418 lin. ft. of elevated beams • 144,018 sq. ft slab on metal deck • 70,343 contact sq. ft. of wall and columns

T

he Talley Student Union project would be the biggest project bid to date for the contractor. Paying attention to weather conditions, an aggressive construction schedule and the untimely passing of the project’s starting superintendent proved this project would be anything but normal for Briegan Concrete Constructors.

Watch out for North Carolina weather!

Concrete contractors know air temperatures and weather conditions

can be difficult to predict and can make or break any concrete job. The quality controls put into place for all types of weather can be necessary within a day in this region.

“During the course of the project, we encountered cold weather conditions and hot weather conditions,” says Jackson Phillips, Project Manager.

“On February 15, 2013 at 2 p.m., the temperature was 61 degrees. By 11 a.m. the following day, it was 35 degrees and snowing.”

The pours made during the hot weather required special attention to specific actions such as adding chilled water, retarders and ice to

the concrete mix. Reduced delivery times and early morning pours were also incorporated into the placement schedule to reduce the delivery time frames, premature setting of the concrete and beat the heat during the middle of the day.

Conversely, the pours made during cold weather had a different set of requirements to avoid letting the concrete freeze. In this case, hot water and accelerators were added to the mix and in some situations, heating was required. Blankets were also placed on top of the concrete after finishing in an effort to avoid exposure to the cold temperatures. Other

14 Concrete Contractor | December 2014 | www.forconstructionpros.com/concrete

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By itself, the structural slab contained over 1,600 cu. yds. of concrete across 28,000 sq. ft. of slab surface area and had an extreme amount of drops, beams, depressions, elevation changes, rebar, post tension cables, and angles to construct. Photo Credit: Briegan Concrete Constructors parts of the country get a lot colder than Raleigh, NC that is for sure, noted Phillips, however this region of the country has more freeze-thaw cycles than do the colder northern climates which presents challenges as well. When we talk about cold weather conditions, whether it is New York or North Carolina, we are talking about how the ACI describes cold weather.

Location, location, location The location of Briegan’s concrete supplier’s concrete batch plant was also a challenge. Briegan first selected a concrete supplier with a haul time of approximately 30 minutes to the jobsite from their main plant. Traffic and North Carolina summer temperatures became an issue in order to stay within the specifications and ACI requirements for time and temperature as the summer months approached. Briegan developed a backup plan with another supplier and submitted design mixes for approval. Briegan changed suppliers during the course of the Phase 1 foundations to a supplier that had a plant closer to the project location which minimized the challenges of the hot weather concrete operation.

Once this change was implemented, the concrete was delivered within the specifications for time and temperature and work was able to continue without interruption

or schedule impact. In order to lessen the impact on the university and students, the slab pours were placed starting on Saturday beginning at midnight. With the quantities of concrete being placed, and pump staging logistics, two concrete pumps were utilized.

Concrete trucks were staged on campus and were directed via radio communication as to which concrete pump needed the truck. The largest of the two slab pours was 1,000 cubic yards and was placed in seven and a half hours.

The Mohawk

Area A became commonly known as ‘The Mohawk’ due to its shape and appearance from an overhead view.

The first floor use is the loading dock area. The second floor was food service and dining areas overlooking

the plaza. Since the university’s requirement was to keep the existing building operational during the expansion and utilize the new building for NC State Students by the spring semester, Senior Project Superintendent Jamie Mehrich and his crews had a limited amount of time to perform their work. “We were quick to install the Area A cast-in-place foundations and walls so the main challenge of the project could begin — which was the construction of the structural slab.”

Located over the loading dock area, the height from the loading dock level to the structural slab was 24 feet. By itself, the structural slab contained over 1,600 cubic yards of concrete across 28,000 square feet of slab surface area and had an extreme amount of drops, beams, depressions, elevation changes, rebar, post tension cables, and angles to construct. To construct the structural slab, two pours were required. Both pours used site added Super P to have max slump for beams, around post-tension cables and heavy rebar.

When a tighter slump was needed for all the steps and elevation changes it was left out.

Remembering Project Superintendent – Roy Dunn Sr.

Roy Dunn, Sr. started the project for Briegan Concrete as the Project Superintendent. Sadly, “Big Roy” passed away during the first part of the project. “His lead by example,

Contractors with Briegan Concrete Constuctors were tasked with building the cast-in-place foundations and walls. This is the foundation of the area known as The Mohawk.

Photo Credit: Briegan Concrete Constructors

www.forconstructionpros.com/concrete | December 2014 | Concrete Contractor

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Foundation/ Walls

Pictured here is a post-tension beam prior to the concrete pour.

Photo Credit: Briegan Concrete Constructors

get the work done ethic inspired those around him to perform their best,” notes Kenneth C. Tiffany, Vice President at Briegan Concrete Constructors. “The Talley project cannot be remembered without reminiscing of Roy Senior’s dedication and commitment to his projects and Briegan Concrete. We not only lost his jobsite leadership, we lost a long time friend and ally.

Few give all to the success of their projects and company as Roy did for many years,” says Tiffany. “Jamie Mehrilch was brought in from another project to take over for Dunn, Sr. Jamie stepped in big and took control of the project in a very short time period.”

There was a lot going on that Roy was taking care of. The task for

Mehrlich was to get to know the fast moving project while keeping it going forward which he was able to accomplish and complete the Phase 1, north addition on time.

Jim Carlson was the Project Superintendent for the Phase 2 portion of the project which was the south and west additions of the New Talley Student Center. Carlson’s challenges on the Phase 2 additions were the demolitions and structural steel erections taking place within the existing building areas while coming out of the ground on the new additions. The work areas were tight, deliveries and daily operations had to be coordinated closely with Rodgers-Russell, JV, the Projects Construction Manager.

There was a tremendous amount of activity in a small area noted Carlson. Rodgers-Russell and Briegan Concrete’s coordination

The contractors deployed a 45 meter Schwing concrete pump to assist in the placement of the concrete. Photo Credit: Briegan Concrete Constructors

between other subcontractors and safety were key to the success of the South Addition. Throughout the project, Eileen Tiffany, President of Briegan Concrete Constructors, Kenneth C. Tiffany, and Roy Dunn Jr, Vice President of Field Operations, participated in lead management roles on the project. While Kenneth and Dunn concentrated on production and quality control, particularly with the structural slab, Eileen focused on accounting and the contract side of the project. Despite the challenges, Briegan Concrete Constructors was able to manage the schedule, job complexities, personnel changes, weather, safety and logistics to safely complete the project on schedule. The project’s Design Team, Construction Manager at Risk Rodgers-Russell, JV and the North Carolina State University officials are a key component to Briegan’s success on this project.

The Area A cast-in-place foundations and walls were constructed so the main challenge of the project could begin – the construction of the structural slab.

Photo Credit: Briegan Concrete Constructors

16 Concrete Contractor | December 2014 | www.forconstructionpros.com/concrete

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.

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FROM REPAIR TO ONE-OF-A-KIND MASONRY WORK, THERE’S A SAKRETE® SOLUTION FOR ALL YOUR CONCRETE PROJECTS. SAKRETE® Flo-Coat Resurfacer is a highly flowable material that can be easily applied with a squeegee, making old concrete look like new again without the expense of replacement. The originator of pre-mixed bagged concrete, SAKRETE® has offered contractors and do-it-yourselfers innovative, readily available solutions longer than any other brand. Let us help you find the right product for your project.

Visit us at sakrete.com or call 866-725-7383.

Visit us at the World of Concrete at Booth #S10639 to see new products and project demos.

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Spotlight on Decorative Conservatory Green is the focal point for the Stapleton Denver redevelopment project.

Photo Credit: Colorado Hardscapes

Lithocrete sedimentary landform walls Fire pit with form finish concrete

Colored broom finish paving Sandscape planters

Conservatory Green

EMBRACES Community

A new community, nestled in a redeveloped part of town, starts to buzz with new activity. Once a bustling airport, the Stapleton Denver redevelopment now flourishes with new life as mixeduse developments embrace the suburban location and lifestyle.

18 Concrete Contractor | December 2014 | www.forconstructionpros.com/concrete

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Project Profile: General Contractor: Mortenson Concrete Contractor: Colorado Hardscapes Landscape Architect of record: AECOM Owner/Developer: Forest City/ Stapleton Location: Denver, Colo.

Construction: May 2013September 2014

T

he latest development of Conservatory Green seemed to spring up overnight, with hundreds of new houses springing up surrounding the new infrastructure. But tucked inside this newest development sits a gentle park as the focal point of the new community. At the grand opening ceremony, a representative from Stapleton stated how places like Conservatory Green bring people together and this new development exemplifies the hopes and dreams of the community.

Part of bringing the community together starts with the open spaces.

Colorado Hardscapes had the opportunity to take part in one of the primary open spaces for this latest Stapleton development. This park embraces the community; no jungle gym sits on the land, but instead spaces for gathering and interaction flourish. A large grassy hill with amphitheater seating and steps create a perfect setting for weekend and evening activities. Long planters with a comfortable cantilever encourage people to sit. A water feature trickles in the sunlight with a peaceful reflecting pond, but also welcomes kids to play and splash. Large plaza spaces invite neighborhood events like farmer’s markets and concerts.

A warm fire pit with a graceful overhead canopy provides comfort and shelter on Colorado’s chillier nights. But this masterpiece amidst the Stapleton Denver redevelopment did not happen overnight. The design began with visions of Colorado’s

wheat fields swaying in the summer wind. With the prairie concept, the lines of the paving, walls, canopies, firepits, and overall layout of the site emerged. As the vision grew, so did the complexity of the hardscaping package.

The owner, the landscape architect, and the general contractor all knew of the challenges which came with the complexity, so they sought out the expertise of Colorado Hardscapes. Although they all knew Colorado Hardscapes’ initial cost of construction may be higher than others, they also understood the value they would receive. Colorado Hardscapes went through the bidding and pricing exercises. The numbers came back higher than expected, so they worked with the general contractor and the developer to figure out the best way to package the hardscaping work to achieve the best results where it mattered most.

One of the landscape architects on the project, Laurel Raines, Principal at Dig Studio states, “We were glad that the owners were willing to spend the extra money on this project to choose Colorado Hardscapes to perform the work.”

And with the high expectations set, Colorado Hardscapes now had to perform the work and ensure the quality met and exceeded those expectations.

Colorado Hardscapes’ scope included many challenging concrete conditions including Colorado’s monsoon season, walls with a reverse batter which required being stripped and finished for Sandscape, placing Lithocrete sedimentary walls at a slight radius with sloping angled tops, all while maintaining the level of quality expected of their crews.

Colorado Hardscapes’ crew started to work on the new park in the summer of 2013. Summer in Colorado generally complements the construction season, however, this year Colorado experienced a heavy monsoon season. The general contractor had the areas graded for us several times and the rains washed out the site repeatedly. The walls and

Crews started work on the project during the summer 2013.

Photo Credit: Colorado Hardscapes

forms found themselves underwater on many occasions and the crews just had to wait until the sun dried up the site again for decent working conditions and to sneak in some concrete pours before the next downpour. This slowed down progress immensely, but the crews and the general contractor kept at it to keep the project on track.

Making mock-ups

The Lithocrete sedimentary walls also posed a potential challenge. The new trend of sedimentary walls allows for designer creativity, but it also allows for misinterpretation. To overcome any misleading concepts, Colorado Hardscapes installed several wall mock-ups prior to construction of these walls. Mock-ups are a standard

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www.forconstructionpros.com/concrete | December 2014 | Concrete Contractor

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Spotlight on Decorative practice for Colorado Hardscapes, and they installed mock-ups for the tie flatwork on-site for this project as well, but the mock-ups for the walls were crucial for the success of the project.

These mock-ups showed the colors, the final texture, and the angle for the top of the wall. After several renditions of the mock-ups to perfect the colors, finish, and tops, the landscape architect, Kaia Nesbitt of AECOM, chose a smooth form-finish sedimentary wall and approved the on-site mock-up.

The mock-ups took several weeks to complete and perfect for approval, but eliminated any confusion and potential tear-outs in the future.

Once approved, the crew poured a 13 foot long section for practice as well. The crew placed the mockups and practice wall in the summer, however they didn’t install the first official sedimentary wall until November, when they had winter fighting against them too. The

Colorado Hardscapes’ Scope of Work • 317 sq. ft. of concrete splash strip • 13,496 sq. ft. of 4” concrete paving • 20,295 sq. ft. of 6” concrete paving • 106 lineal ft. of sedimentary walls • Concrete fire pit • 632 lineal ft. of Sandscape finished concrete planter walls • 101 lineal ft. of stage wall with Sandscape finish • 440 lineal ft. of Sandscape concrete landform walls • 40 lineal ft. of landform concrete curbs • 974 sq. ft.of amphitheater concrete bench steps • Concrete stairs at stage and amphitheater • Concrete bases for site furnishings and pavers • 257 lineal ft. of concrete curb at burm • 472 lineal ft. of concrete edger • 354 lineal ft. of Sandscape planter curbs • Water feature installation

sedimentary walls required arched forms and additional tie wire for width support for the complex pour.

Because of the nature of sedimentary walls, the pours moved a little slower than a traditional wall and required three different loads of concrete timed perfectly — one after the other in order to maintain the structural integrity of the wall.

The landscape architect designed beautiful Sandscape planter walls which tilted outward into the plaza space. This design helped simulate the wheat flowing in the fields, and also provided comfortable seating for people with a little undercut to rest their legs. However, with the great design concept of the walls came the construction feasibility challenges. To achieve a consistent Sandscape finish of the surface of the walls, the forms needed to be stripped in order to finish. But with the cantilevered edge, our crews feared the walls would tip and collapse if they stripped the forms too early. The cantilever needed braces to support the forms, so removing the braces and the forms required extra time and care. Not every wall pour went perfectly, some fell and the crews installed those walls more than once.

The final scope of Colorado Hardscapes’ work at Conservatory Green included: Sandscape planter walls, landform walls, Lithocrete sedimentary walls, Sandscape planter curbs, water feature, fire pit with form finish concrete, all survey and layout, colored broom finish paving, colored Sandscape paving,

A smooth form-finish sedimentary wall was approved after several mock-ups were completed to show the colors, the finish and the tops.

Photo Credit: Colorado Hardscapes

uncolored broom finish paving, and the radial slanted amphitheater benches. The developer unveiled the new park to the community this summer with the promises of community interaction. The attention to detail in both the design and construction makes this project unique.

The complementary use of landscaping to soften the hardscaping creates a very comfortable space.

The sedimentary walls required arched forms and additional tie wire for width for width support for the complex pour.

Photo Credit: Colorado Hardscapes

20 Concrete Contractor | December 2014 | www.forconstructionpros.com/concrete

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Interior Flooring: Year-Round Opportunities. Cold temperatures, rain, snow, whatever the weather conditions, interior decorative flooring provides year-round project, and profit, possibilities. From epoxy based systems to rich stains of variegated color, Increte Systems is your One-Stop-Shop for the most complete line of products and engineered systems to create distinctive surfaces to meet the demands of any decorative flooring project.

Granite Coat

Level Top SP

The Look of Terrazzo The Durability of Epoxy.

Granite Coat Epoxy Vinyl Chip System is the fast and economical means for creating a colorful surface to complement any residential or commercial interior décor. With a pigmented epoxy base coat, the six combinations of vinyl chip colors may be applied from sparse to full surface coverage for a distinctive durable terrazzo-like surface.

Rejuvenate Interior Concrete Flooring Surfaces and Finish in Record Time!

Level Top SP’s unique self-leveling formula allows you to create a new, durable surface that is walkable and stainable in only 4 hours, and polishable in just 24!

Level Top SP is the perfect solution for transforming dull, worn interior concrete into new decorative possibilities.

Metal FX

Quartz EP

Colorful Seamless Surfaces.

Like all Increte epoxy systems, Quartz EP allows you to create a slip-resistant, durable and low maintenance flooring surface perfect for residential or commercial applications.

Available in a spectrum of colors, the resulting seamless surface delivers a colorful enhancement to any interior décor.

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Stone Essence

Rich, Variegated Color without the Negatives. The 20 colors of Stone Essence are ideal to create the rich variegated beauty of an acid stain without the prohibitive and problem-matic odor and residue clean-up issues associated with reactive stains. The concentrated formulas of Stone Essence offer economy and application ease plus the ability to dilute and/or mix colors for unlimited possibilities.

Dramatic. Durable. Low Maintenance. These describe a Metal FX Metallic Effect Epoxy flooring surface. 10 standard pigment colors are only the start of outstanding possibilities. Two or more colors may be applied for unique effects and “One-toOne” pigment combinations offer an added array of distinctive colors. A variety of application techniques can create effects that make each Metal FX surface “One-of-a Kind.”

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GFRC/FRC/ECC

Admix Trinic GFRC Admix

Trinic GFRC Admix takes the hassle out of making ultra high performance Glass Fiber Reinforced Concrete, Reactive Powder Concrete, and Engineered Cementitious Composite Concrete. It’s easy to understand and dose, simplifying what can become an overly complicated process.

Advantages • Multi component powdered admixture simplifies the production of GFRC, RPC, and ECC mixes • Proven though independent testing to eliminate the need for 7 day wet cure of GFRC products: outperforms control samples by over 500 PSI in flexural tests • Eliminates the overnight shipping costs in winter, foaming, separation and moldy product problems associated with liquid polymers

Trinic Plasticiser A proprietary blend of a powdered plasticiser with dispersing and wetting agents for the production of ultra high performance wet-cast and GFRC concrete.

Advantages • Faster blending, easier wetting out of cementitious paste and color components • Increases compressive and flexural strength • Makes the production of high performance low water to cement ratios possible

Trinic Stage II Powder Accelerator/Hardener Concrete goes through three distinctive hardening/curing stages. During the first stage little or no strength is gained.

During the second stage as much as 1,500 PSI per hour in strength gains can be realized, during the third stage strength gains of 50 PSI per hour happen. Ordinary accelerators start working the second they contact the cement, shortening the working time of stage one. Trinic Stage II Powder Accelerator/Hardener is designed to start working during the second stage of strength development.

Advantages • Increases the early and ultimate strength of concrete with minimal effect on initial workability • Offsets the retarding effects of high plasticiser dosages while reducing pozzolan strength lag • Delivers excellent results in normal and cool conditions where very high next day strengths are required

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Concrete Solutions for Your Concrete Needs

Trinic Training FREE classes are provided each month for your success

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info@trinic.us 11/12/14 11:56 AM

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Spotlight on Decorative

CHEF JOHNS

This 16 year old restaurant floor looks as good as the day it was installed.

By Joe Nasvik

L

udington, a small Michigan town along the north eastern shore of Lake Michigan, is where John Stapleton decided to open his own small restaurant — it was time. He had worked as a chef for two of the larger restaurants in town and also a grocery store chain, preparing hot food for customers on order. He says he was fired from that job for being too customer oriented — hence the decision to open his own place. That was in 1998 and “Chef Johns,” the name of his restaurant, has been serving the area ever since.

Stapleton rented a storefront building space that semi-trucks once backed into, so he knew the concrete floor was thicker than usual. The last owner, a gymnastics studio, glued grass carpet to the floor, making it impossible to know the condition of the floor, but the concrete turned out to be in good shape.

Stapleton didn’t really have any ideas about how the customer side of the restaurant should look.

About this time he met Laurie Carey and her friend Shirley Reed at a local entrepreneur class. Carey is a professional local artist who works in several mediums and has done a lot of work in the area. She was interested in doing concrete floor artistry so she volunteered to do the work at no charge if she could have artistic control, something Stapleton

readily agreed to. Carey and Reed working together designed the wall spaces and the bathroom and also did the work. They rounded up the materials they needed from garage sales and other places. The result is unique, everything coming together to provide a nice atmosphere.

The restaurant opened with three tables from Stapleton’s house, allowing 15 customers at one time.

Later on, when he added another bathroom, the health department permitted the occupancy to go to 50 people. So customers and friends brought in their old dining room tables, chairs, and table cloths.

Nothing matched and that became part of the charm too.

Preparing the floor

The first challenge was to remove the grass carpet left by the previous occupant of the building. Stapleton

Laurie Carey, the artist who installed the decorative floor, built a platform on wheels to scoot herself and her paints around the floor.

Photo Credit: Laurie Carey

ripped it off the floor and planned to grind off the troweled adhesive but Carey asked him not to, thinking that it might help make the joints between her paving stones look dirty and more natural. So the only preparation ended up being the removal of the carpet and anything that prevented a flat installation.

Working alone, Carey did the rest of the work.

Doing the work

This project was Carey’s first attempt at faux decorative concrete work and she was free to design what she wanted. She envisioned a three dimensional large spiral paving

24 Concrete Contractor | December 2014 | www.forconstructionpros.com/concrete

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COLOR SOLUTIONS

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BlueConcrete provides the widest range of color available for coloring concrete. We provide blending, packaging, and color matching solutions for consumers and manufacturers alike. Let Blue Concrete manage your color offering and realize cost savings, consistency, and a cleaner working environment.

Buddy Rhodes Concrete Products provides a wide range of materials and blended concrete mixes for artisan concrete. Artisan concrete can be counter tops, fireplace surrounds, furniture, and many other architectural elements. Our products result from the hands on experience of seasoned professionals and from Buddy himself.

In summary, we are a solution provider. Let us find a solution for you.

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Spotlight on Decorative Chef Johns Restaurant is where locals like to meet for breakfast and lunch in Ludington, Mich. After 16 years in business, guests still debate whether the faux decorative concrete floor is real or not.

Photo Credit: Joe Nasvik

stone pattern on the approximately 1,000 square feet of floor. To install the work, she built a small platform on wheels about four inches off the floor, big enough to hold herself and her cans of paint. With this she scooted herself around and add color to the floor. Because it was a voluntary project being done for a friend, she was able to work during off-hours — no workers to walk on her fresh paint and all areas being accessible.

Carey decided to use regular water-based interior latex house paint to do the work and she recalls painting six colors to achieve the three-dimensional effect. Work started by chalking the pattern on the floor. So she painted over the chalk marks and left over carpet adhesive, going over each area several times adding different colors until she got the look she wanted.

Final seal and maintenance Ideally, floor traffic should walk on the floor maintenance system and not the decorative floor finish.

Stapleton was concerned that foot traffic would quickly wear through Carey’s work. He also needed a sealer that didn’t soften or absorb oils from food spills. So he sealed the floor with water-based urethane.

His regular maintenance involves sanding the floor every year with 300 grit sandpaper and applying a new application of urethane. This regular maintenance has preserved

construction but it’s doubtful one was included when this floor was placed in the mid 1970’s. Using nonbreathable sealers and products on these floor surfaces can be risky, resulting in discoloration and sealer failure. In rare cases trapped water vapor can even cause concrete to scale. However, products allowing water vapor to pass through, while not allowing liquid water to penetrate, helps to prevent these kinds of problems. Still, concrete doesn’t always follow the rules, and this can have both positive and negative consequences. Before attempting a decorative floor project it’s good practice to be sure the products being used are breathable.

The restaurant today

The rock patterning is very three dimensional, giving the impression that one should walk carefully.

Photo Credit: Joe Nasvik

the original work and the floor looks as good as it did sixteen years ago when it was installed — no significant amounts of spalling or scaling finish.

A word of caution

Water vapor naturally moves from the sub-soils under concrete slabs through the concrete and into the air. This can be prevented by installing vapor retarders between the soil and concrete at the time of

Stapleton sees new customers frequently argue about whether the paving stones are real or not. Many people lean over in their chairs and feel the floor to be sure it’s flat — feeling is believing. People also have a tendency to step on the center of the large stones so their feet don’t catch in the joints; Carey’s pavement is very realistic.

If you have the opportunity to visit Ludington, be sure to stop at Chef Johns for breakfast or lunch.

Check out Carey’s work, and the homespun creativity that provides great atmosphere. Be sure to look at the bathrooms too, you’ll never see anything like them.

Be sure to greet John Stapleton also, he can be found in the kitchen area where he makes ten different types of bread each day, pastries and cinnamon rolls, and soups which he is locally known for. Both Carey and Stapleton are recognized for their artistry in the Ludington area.

26 Concrete Contractor | December 2014 | www.forconstructionpros.com/concrete

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Decorative Products McKinnon Aurora Epoxy Dust Aurora Epoxy Dust is a fusion of metallic epoxy pigments that reflect light rather than absorb it to produce a floor with depth and dimension.

• High-tech nano-pigment • Colorants are influenced by the systems and substrate they are placed upon • Add to a clear epoxy binder to achieve seamless floors ForConstructionPros.com/10276993

NewLook EffLock Admixture

Color-Matic I Liquid Color Dispensing Unit

The nano-fusion admixture EffLock reacts with and permanently binds sodium impurities in the concrete to stop efflorescence in concrete and masonry.

• Water-based • Prevents efflorescence for the life of the concrete • Positively contributes to curing and the use of densifiers and penetrating sealers • Available in liquid, powder admixture form or as a topical spray for existing surfaces

Increte’s Color-Matic I liquid color dispensing unit is designed for ready-mix, precast and decorative or construction supply facilities.

• 12-in. industrial color touch screen control • Batch history stored and easily retrieved • Peel-n-stick label printer for every batch • Nozzle rinse to eliminate clogging • Auto recycle • Three different size storage totes: 110-gal. conical, 250-gal. IBC and 350-gal. conical • Four color storage totes • Four dispense pumps • Lower power requirements and smaller footprint than other Color-Matic systems • Accuracy within .2 lbs.

• Dispenser dimensions: 4-ft. by 4-ft. by 4-ft.

• Tote dimensions: 30 in. by 30 in. by 60 in.

• Electrical: 110V • Air requirements: 15 cfm at 80 psi • Water: 5/8-in. line

ForConstructionPros.com/11249248

QUIKRETE Translucent Concrete Stains QUIKRETE Translucent Concrete Stains create a semi-transparent appearance that highlights the natural variations in concrete and masonry surfaces.

• Water-based, polymer-bonded stains • Multiple color combinations to achieve a unique, multi-tone layered appearance that will not peel over time • Available in red, terra cotta, cola, light brown, light gray, gray, blue, golden wheat and brick red • Ideal for decorating garage floors, driveways, pool decks, sidewalks and patios ForConstructionPros.com/11302278

ForConstructionPros.com/11282959

BOOST! from SUPER-KRETE SUPER-KRETE International, Inc. presents Concrete BOOST!, a ready-mix concrete booster that makes concrete stronger, harder and waterproof.

• Designed for smaller batches of concrete for use with a ready-mix sack up to 90 lbs.

• Can be used with any Portland cement-based material • One bottle will improve the overall matrix of the concrete by increasing strength up to 23%, waterproofing the concrete, resisting shrinkage cracks and improving the workability of the mix • The treated concrete results are reduction in permeability, efflorescence, susceptibility to freeze/thaw damage and resistance to water, radon and chloride ion intrusion • In concrete countertops, it will help keep slabs from curling as they cure ForConstructionPros.com/12005471

ARDEX EP 2000 Substrate Preparation Epoxy Primer Two-component, 100% solids epoxy resin primer formulated for use with ARDEX Underlayments and Toppings.

• •

• •

Suited to prime concrete and other structurally sound and solid substrates Install over: terrazzo, epoxy coatings and ceramic and quarry tile, prior to installing ARDEX products Packaging: 10 lb. (4.5 kg) Coverage: 150 to 200 sq. ft. (13.9 to 18.2 m2)

ForConstructionPros.com/12006556

28 Concrete Contractor | December 2014 | www.forconstructionpros.com/concrete

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Helix Architectural Color Hardener ChemSystems, Inc., a manufacturer of the Helix brand of decorative concrete colorants and admixtures introduces Helix Architectural Color Hardener, a dry shake surface color hardener containing reflective aggregate designed to produce an elegant and refined light exposed colored concrete surface.

All-in-one product that combines the benefits of color hardener with specialty selected and graded reflective aggregates. Once applied, the surface is lightly exposed using Helix Surface Etch exposed aggregate surface retarder grade 01 or 03, or an acid wash using Surface Gel Tec HD24 gelled acid.

The resulting finish is a lightly exposed and refined colored concrete surface with reflective aggregate adding sparkle and shine to the surface.

• Available in six standard colors with three different reflective aggregates (glass, mirror and carbide) • Custom colors or aggregates are available upon request.

• Long range benefits include increased service life of the concrete, increased light reflectance, increased coefficient of friction reducing slip issues, and increased aesthetic value from colored concrete • Once the concrete has cured, seal with Helix Super Seal SB, a penetrating waterproofing sealer is recommended to provide protection against water, oil, deicing salts and other common forms of contamination

Trinic H-12 Sealer Trinic is proud to introduce H-12 Sealer for concrete countertops and floors.

The H-12 was designed to fill a void in the industry for an easy-to-apply mostly penetrating sealer that protects the surface from stains as well as etching from acids without diminishing the look of the concrete.

• H-12 waterbased sealer is scratch resistant and easy-to-apply • Color enhancing • UV stable • Adheres to extremely dense concrete ForConstructionPros.com/12019794

EPOXY • METALLICS • NATURAL STONE • OVERLAY POLYASPARTICS • URETHANE • SEALERS

www.mckinnonmaterials.com

TOLL FREE 1-866-622-7031

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LARGEST IN-STOCK SELECTION OF EPOXY STONE

Stone Bond Epoxy

ForConstructionPros.com/12008183 Aurora Epoxy Dust A reflective metallic pigment that creates a unique 3-D visual effect.

Mix two colors for even more inspiring color results.

McKrete™ Dry Mix & Additive Indoor or outdoor, this user-friendly acrylic material can be stenciled, taped or textured.

Winning Results This “checkered flag illusion” was created using Black & White Industrial Epoxy, protected with our High Performance Urethane.

Arcadian Stone Form Liner Butterfield Color introduces the Arcadian Stone Form Liner, the latest addition to the company’s line of step and form liners. This rustic stone form liner provides the look of a rustic stone edge in either a 2” or 4” thickness.

• Works well for steps, wall caps, countertops, etc.

• The Arcadian Stone Form Liner is unique in that the face texture tapers to provide a fluted line where the edge face meets the slab surface • Offers a very realistic stone slab look

McKrete™ Dry Mix & Additive Indoor or outdoor, this user-friendly acrylic material can be stenciled, taped or textured.

Winning Results

Urethane.

Chromastain Eco-friendly waterbased, self-sealing stain penetrates and adheres to porous surfaces for custom blending and shades.

Custom-Tinted Industrial Epoxy

ForConstructionPros.com/12021345 www.forconstructionpros.com/concrete | December 2014 | Concrete Contractor

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epoxy | Metallics | Natural stoNe | overlay | polyaspartic | urethaNes | sealers

Stone Bond Epoxy

Stone Bond Epoxy

Stone Bond Epoxy

Stone Bond Epoxy

epoxy stoNe systeM- Beautify and protect even very uneven concrete surfaces. Used in residential applications around pool decks, patios, lanais, and porches. Can also be used in driveways, garages, walkways, entries and cellars.

Epoxy Stone is particularly useful in pool areas because it helps eliminate puddles and standing water.

McKrete™

McKrete™

McKrete™-— Patented acrylic and epoxy cementitous material applied over existing concrete.

This versatile material can be installed using a variety of stencil patterns and colors.

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coNtact us toDay! www.mckinnonmaterials.com Toll Free: 1-866-622-7031 Visit us on Facebook

Industrial Epoxy

Industrial Epoxy

Paint Chip

iNDustrial epoxy-— Contains an additive in the resin to make it harder and an additive in the cure to make it chemical resistant. Can add paint chips or have custom tinted to a color of your choice for that ideal concrete coating color match.

aurora epoxy Dust—

Chromastain

chroMastaiN— An environmentally friendly water

Industrial Epoxy

based stain designed specifically for porous substrates including concrete, acrylic and concrete overlays systems.

It penetrates, adheres to the surfaces and is self-sealing.

Base color blending allows for hundreds of color combinations.

Intended for use as a metallic epoxy floor system, countertop system, or other horizontal surface to create one of a kind unique designs to enhance any epoxy floor coating. Unlike acid stains and standard coloring methods, the pigments in this metallic epoxy reflect light rather than absorbing it creating incredible depth and dimension.

crystal coat - Enhances the color and intensity of the pavers while providing a fortified, protective shield.

It’s strength and durability as to wear/abrasion resistance, substantially decreases routine cleaning and maintenance costs while forming a penetrating locked in place bond.

Specifically formulated to withstand the harsh forces of Mother Nature and continuous UV rays of the sun. At $93 for 5 Gallons, Crystal Coat is an inexpensive paver solution!

Crystal Coat

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Aurora Epoxy

12/2/14 1:05 PM

Decorative Products Buddy Rhodes Concrete Products Catalog of Products and Techniques Buddy Rhodes Concrete Products, a member of the Delta Performance family of companies, is proud to announce the release of the company’s Catalog of Products and Techniques. This catalog is a compilation of stories, recipes, tips and tricks, and information about their complete product line.

• The publication represents multiple decades of experience with Artisan Concrete from Buddy Rhodes and the staff of experienced concrete artisans • Available for free download at www.buddyrhodes.com • Will be available as a hard copy in early 2015 ForConstructionPros.com/12021348

H&C Dry-Shake Color Hardener & Release

Concrete Solutions Trowel-Top

Dry-Shake Color Hardener & Release is formulated for coloring and hardening new stamped concrete applications.

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32 Concrete Contractor | December 2014 | www.forconstructionpros.com/concrete

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Charging System

Charging Batteries

by INDUCTION

Will this spark another revolution in the cordless tool industry?

I

n 2006/2007 companies that manufactured tools for the construction industry introduced lithium ion batteries (Li-ion) as a replacement for nickel cadmium batteries (NiCad). NiCad served the industry well for several years. No one at that time knew what voltage platforms would serve the needs of tradesmen the best so several different voltages appeared on the market; 12, 18, 24, and 36 volts were all part of the introduction. It was thought the transition would take several years but NiCad batteries quickly became a thing of the past, the industry changed in a years’ time. Since then the continued development of Li-ion batteries, more energy efficient motors, and sophisticated monitoring software in tools, batteries, and chargers increased performance even more. As a result manufacturers are converting more energy intensive corded tools to cordless. The introduction of Lithium batteries changed the way we work with tools.

There may be another game changer in the works. Bosch Tool Company has just introduced a wireless charging system (also called induction charging) for charging batteries — on the tool or off — and it might influence the way we work with hand-held electric tools.

Background

The idea of transferring electrical power from one place to another without a mechanical connection isn’t new, it’s at least one-hundred years old. Its been known for a long time that a coil of copper wire charged with an alternating current creates a magnetic field around it which can be used to transfer energy to another copper wire coil position within the magnetic field. This electrical energy can be used to charge batteries or to run a device. Today there are induction cooking stoves that pass energy from the stoves cooking surface to steel cooking vessels. In this case the current transfer produces energy in the form of heat to cook food in a very efficient manner, bringing water to boil very quickly.

Currently induction power transfer is also being used to charge cell phones, electric tooth brush batteries, and to power medical devices inside human bodies.

Bosch’s new induction charging system for tool batteries includes a charging pad (right) and a battery (left) that includes a coil of wire located just under the red plastic bottom of the battery. No mechanical connection required.

Photo Credit: Joe Nasvik

How it works

Jason Feldner, Group Brand Manager for Bosch Power Tools and Accessories, Mount Prospect, Ill., says the idea is simple; induction charging occurs when an AC current passes through a coil of copper wire, creating a pulsating magnetic field around the coil.

When a second coil of wire is placed within the magnetic field, electrical energy passes from the magnetic field to the second coil and energy is stored within the battery cells.

“The technical challenge has been to ensure the process works only when the intended battery is placed within range, not when foreign objects, such as a washer or screw, are placed on or next to a charging pad. For

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instance, placing a piece of metal on a charging pad could cause it to become red hot. But sophisticated algorithms and electronics developed by Bosch ensure that the chargers recognize the object is not a battery and will not turn on, a process referred to as Foreign Object Detection (FOD).” Feldner adds that the challenge was also to deliver lots of charging power instantly. So an induction charger must not hurt anything, anyone around it, or on it but still charge batteries quickly.

Historically, induction charging isn’t as efficient as conventional charging — challenging companies researching this technology to improve performance. Feldner reports that the system meets all current energy efficiency standards and charges batteries at the same speed as traditional chargers.

Bosch’s new battery holds the second wire coil located just under the cell pack, so it rests just above the charging pad. Special electronics within the battery and the charging pad communicate back and forth when the battery is placed on the charging pad (conventional charging systems also include electronics).

With this technology, the charger knows charge status and exactly how much energy to pump into the battery. The pad also won’t produce an inductive current if it doesn’t recognize the object on the pad as a wireless charging battery. A warning light on the pad informs the operator that no charge is taking place when this happens. Bosch’s new batteries can still be charged using a conventional charger but older batteries can’t be recharged by an induction charger.

amount of stuff that must be carried onto jobsites and increase user efficiency.

One of the benefits of induction charging is that batteries can remain on the tool — tool and battery together can be set on the charging pad without harming the tool.

Dost says they are making this easier by introducing accessory “holsters” for hammer drill-drivers and impact drivers, and also “holders” that effortlessly secure the battery in position over the charging pad.

“These accessories can free up space on bench tops, carts, and shelves in trucks because they can be located in unused spaces such as under bench tops or on the sides of shelving units,” he adds — batteries can safely be left on chargers for long periods of time.

The benefits of charging by induction • It makes it much easier to keep a cordless tool charged • Fewer batteries will be needed on a jobsite • Increases efficiency and jobsite organization • There is less “stuff” to haul to and from trucks

How inductive charging can benefit contractors

Hagen Dost, product manager, Bosch batteries, says feedback from contractors and tradesmen suggests they don’t like setting up charging stations that include several chargers, power bars, and multiple backup batteries. So this technology is seen as a way to reduce the

The greatest benefit is that tools remain charged and ready, workers use a tool and set it on the charging pad between uses during coffee breaks, lunch or simply between tasks — batteries are constantly

These are the key elements of the system. The element at the bottom resides in the charging pad and produces the electro-magnetic field. In the battery the flow of current goes from the housing at the bottom of the battery to the battery cells above.

Photo Credit: Bosch

charged and work becomes more efficient. This will probably reduce the number of batteries needed on a jobsite too, because batteries are constantly being topped off and users don’t need multiple backup batteries waiting.

Where to from here?

Bosch chose to introduce induction charging with the industry’s most popular voltage platform, the 18 volt 2 amp hour battery (sometimes referred to as a “slim pack” battery).

You can expect to see other voltage platform batteries, such as 4 and 5 amp hour packs on the market soon.

Feldner says this is only a start, they are thinking about dozens of other exciting ways the technology can be applied.

Li-ion batteries changed the hand-held power tool industry when they were introduced; today it’s hard to find any professional tool that still uses NiCad batteries. The revolution continues as tool manufacturers improve battery performance and convert more corded tools that consume larger amounts of power.

Now another revolution may be underway as induction charging technology enters the marketplace.

www.forconstructionpros.com/concrete | December 2014 | Concrete Contractor

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Concrete Anchors

Fastening System Earns Its Stripes with Military Facility Installation

A new fastening system allowed crews to complete the job 70 percent faster than originally anticipated.

By Bob Wolff

I

t happens all the time; some jobs naturally turn out to be tougher and more time consuming than they figured to be. For one reason or another — weather delays, not enough materials, unexpected circumstances or something else — things happen where a deadline is not met or the profit margin takes a hit. Afterwards, it’s only normal if you question why you took on the project in the first place.

You couldn’t blame Nirav Sapra if he had those thoughts running through his head last April when he began work on an important job in western Illinois. The project manager for Lakemoor, Ill.-based Master Design Build had won a $1.5 million project at the Rock Island Arsenal (RIA), a military facility on the Mississippi River in the Quad Citi0es area. It figured to be a challenging task until he discovered a new product that turned the tide.

By using the T3 Insulfast Insulation Fastening System from ITW Ramset, Sapra and his crew completed the assignment to fasten 2-inch insulation to military grade reinforced concrete 70 percent faster than he originally anticipated.

“Using Insulfast was a life saver,” he says. “I originally calculated it would take two of my guys six weeks to complete the work, given the complexity of what was involved. As it turned out, one guy did everything in just two weeks. It was absolutely crazy.”

It’s not Alcatraz but RIA is the Midwestern “rock”. The largest government-owned weapons manufacturing arsenal in the western world, it provides manufacturing, logistics, and base support services for the Armed Forces. An active U.S. Army factory which manufactures ordnance and equipment for the Armed Forces, RIA sits on 946 acres in the middle of the river between the cities of Rock Island, Ill. and Davenport, Iowa.

A major bridge carrying four lanes of traffic on Interstate 74 is positioned off the eastern edge of the property, which was originally established as a government site nearly 200 years ago with the building of Fort Armstrong in 1816. During the Civil War, Arsenal Island was home to a large Union army prison camp for captured Confederate soldiers, but that’s where any comparisons to Alcatraz end.

About 250 military and 6,000 civilians work at the RIA, which contains modern stone buildings to withstand the gritty conditions and wild temperature fluctuations the region experiences annually. Sapra was contracted to upgrade the Vehicle Maintenance facility, a nuts-and-bolts operation that does work on Marine Corp. vehicles. The 3,000 square-foot building was without fire alarm systems when originally constructed, says Sapra, so there was a huge concentration now on installing fire insulation. But there was a catch.

T3 Insulfast helped one contractor finish a job 70 percent faster then anticipated.

Photo Credit: ITW

“The insulation had to be installed in places 45 feet above ground level, and we could not use a scissors lift because of where the existing equipment was positioned.

This meant that my guy had to use a ladder each time. If he had to screw in the insulation at that height, it would have taken us much longer to complete.”

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That’s where Ramset’s T3 Insulfast saved the project. Four times faster than traditional stick pin installation methods, it allows the installer to attach insulation in one simple step without using adhesives or cutting spindle insulation anchors. T3 fastens the insulation directly to solid masonry, hollow concrete block, and even steel studs, so the days of gluing and stick pinning insulation anchors are over.

It also addresses thermal bridging by creating a significant lateral cold or heat flow along the surface of a wall before penetrating through the wall via steel in the pins.

Proprietary fasteners come with the Ramset T3 Insulfast system and provide 211 lbs. of ultimate tension capacity to attach insulation like Rockwool, Expanded Polystyrene, and Extruded Polystyrene. The T3 tool that typically shoots more than 1,000 shots before needing

to be replaced makes it possible to fasten insulation in all the tight places through pipes and sprinkler systems.As Sapra learned, there are exceptions.

“The Vehicle Maintenance facility was built to military grade specs and the concrete was much harder than usual. It was so hard that we did experience some failures; when we shot the fastener through the concrete, some of the nails would bend on the other end. I didn’t have a problem with the product, which I found extremely efficient. We would have saved even more time if all of the work was done at ground level.”

Further complicating the project was the type of insulation used. Sapra remarked that ROXUL FabRock is a new kind of insulation that is very dense and made of stone wool, combining pulverized volcanic Basalt rock found in lava fields with recycled slag, a byproduct of the steel and

copper industry. The minerals are melted and spun into fibers to form insulation boards. A multi-purpose board that repels water and moisture, FabRock is fire resistant and rated to 2,150-degrees Fahrenheit.

“The stone wool absorbs sounds very well and is a fire retardant. That’s why the military has used it in some laboratories and nuclear facilities,” informed Sapra. “It was selected for RIA because of the welding work that is performed in the vehicle shop. It was the first time I worked with ROXUL and it is heavier than standard regulation board. This stuff weighs 10-12 pounds and makes it harder for a person to carry a sheet of it up a 45 foot ladder. Overall, it was a very interesting project and T3 Insulfast saved us a significant amount of labor time. It really lives up to its name.”

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www.flyash.com www.forconstructionpros.com/concrete | December 2014 | Concrete Contractor

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Code Update

Reorganized ACI 318-14 Provides a

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38 Concrete Contractor | December 2014 | www.forconstructionpros.com/concrete

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I

n today’s complex construction environment, as knowledge, experience and uses of structural concrete continues to grow, it is extremely important that all construction disciplines work in synergy with one another.

That is why the reorganized and recently published ACI 318, “Building Code Requirements for Structural Concrete and Commentary,” pays special attention to helping all parties bridge between ACI 318, which guides design, and ACI 301, “Specifications for Structural Concrete,” which guides construction. This was accomplished through an all-new Construction Chapter 26 in ACI 318-14 covering Construction Documents and Inspection. All of this was done with the goal of improving communication between the licensed design professional (LDP) and the contractor community.

ACI has determined that only licensed design professionals (including those on staff of some contractors) are responsible for knowing and interpreting the provisions of ACI 318.

Implications of a reorganized Code for the construction industry.

The reorganized ACI 318-14 follows the design process wherever possible, with a chapter for each type of member. This more intuitive approach provides the designer with confidence that all provisions relevant to a particular design have been addressed.

In the past, the LDP (and to a lesser extent the contractor and supplier) would have to search throughout ACI 318 to find the

required information needed to complete the design for each structural member. The absence of specific direction could possibly lead to an incomplete design. In practice, it was also often assumed the contractor would find the necessary information and requirements in the Code without any explicit instructions in the construction documents.

Importantly, as constructionrelated provisions were collected into a single chapter, the new Chapter 26, it became clear an overall

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organizational structure, unique to the construction chapter, had to be developed. Questions this approach raised and the manner they were addressed include: • ACI determined that only licensed design professionals (including those on staff of some contractors) are responsible for knowing and interpreting the provisions of ACI 318. This decision established the foundation for nearly every other issue.

• For consistency and convenience, the 13 subchapters were organized along the lines of a typical construction specification and all contractor provisions, including concrete proportioning provisions, are now found in the construction chapter.

• Subchapters of the new Chapter 26 follow an internal logic based on the character and enduser of referred to provisions, assigned as Design Information, Compliance Requirements or Inspection Provisions. These latter provisions are formatted in code language that may be transferred directly to the construction documents with minor or no change.

• A large part of the ACI 318 reorganization has the intent of more clearly assigning responsibility among the design-build team and development contract. A new provision requires the LDP to identify work assigned to others and include all necessary information needed for another LDP to design a definable portion of the project.

Impact for the construction industry

The assignment of duties and responsibilities on a complex project and job site can sometimes become problematic. Often, this only becomes germane much later if a lawsuit or inspection issue arises. Therefore, distinguishing between these responsibilities became a priority and directive of the ACI 318 committee.

Chapter 26.1 makes it explicit with respect to Contractor Responsibility that “it is not intended that the Contractor will need to read and interpret the Code,” plus “a general reference in the construction documents requiring compliance with this Code is to be avoided.”

Furthermore, Chapter 26.1 specifies: “This chapter is directed to the LDP responsible for incorporating project requirements into the construction documents.”

The most likely way the LDP will satisfy this requirement is to copy the “compliance requirement” provisions directly into the construction documents as applicable, but the LDP is not required to use the wording in the Code verbatim in construction documents.

At the same time, it has been made clear that “Compliance requirement” provisions transferred to the construction documents are the responsibility of the contractor.

40 Concrete Contractor | December 2014 | www.forconstructionpros.com/concrete

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At the same time, it has been made clear that “Compliance requirement” provisions transferred to the construction documents are the responsibility of the contractor.

Exposure Classes

The Code will require the LDP to assign the Exposure Classes and select the minimum concrete requirements associated with the assigned exposure class in the construction documents.

The contractor/concrete supplier will use the minimum requirements to proportion the concrete mixtures. The 318 committee members made the decision not to accept a pure performance specification for concrete proportioning. If the LDP wants the concrete supplier to select the minimum concrete requirements, the contractor must be instructed to do so and the exposure classes must be explicitly stated in the construction documents.

Summary

It is the belief of ACI Committee 318 the reorganized ACI 31814 reflects the real world design process as much as possible. It is easier to understand by students and others new to the construction industry, and will be adaptable as advances are made in the use of structural concrete.

Specifically, the new construction chapter of ACI 318-14 provides contractors with the information, direction and clarity needed to fulfill their responsibilities on any project.

Ed. Note: For more information, visit www.concrete.org/ACI318.

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Foundations Q&A

The Truth About High Humidity in NEW Foundations The Concrete Foundations Association explains the frequent concern lifted by homeowners for the presence of moisture in their new basements.

By James R. Baty II

Question I’m having a hard time convincing some homeowners that they don’t have a drainage problem but rather that they need a dehumidifier in their new basement to offset the effects of the humidity in a foundation. – Concrete Contractor (Iowa).

Answer This is an age-old question that homeowners ask and should ask when taking over the responsibilities of a new home.

Depending on what information the builder communicates to that home owner at the time of possession, the foundation contractor may very well be involved in an early concern for the presence of visible moisture in areas of little or no air movement in the new basement.

First, let me relieve your stress about the presence of that moisture.

Is your wall leaking? That is not very likely and in all probability, the potential for that to be of concern is extremely low. Monolithic concrete foundations should be waterproofed and they likely have active drainage systems, however, unless you’ve experienced a flood condition recently, the moisture in a new home is being generated by the wall itself in consort with the non-moving air of the basement and the relative humidity of that air.

The industry standard for castin-place concrete is a maximum water-cementitious ratio of 0.45.

This means that all concrete in the walls and slab are roughly 45 percent water by volume at time of placement. The process by which the

material hardens to solid concrete is called hydration, a chemical process where the cementitious particles react with the free water and produce crystals. This process consumes a large amount of the water during the process and gives off heat.

The rest of the construction process involves building a home from the foundation. The more the home takes shape, the more protection or envelope is built around the concrete adding protection from taking on more moisture (active exposure to the elements) but also preventing evaporation from working

to lower the humidity. The National Ready Mixed Concrete Association, in their CIP 28 bulletin for concrete slab moisture offers: “Allow sufficient time for the moisture in the slab to dry naturally while the floor is under a roof and protected from the elements. Avoid maintenance and cleaning operations that will wet the concrete (floor). Use heat and dehumidifiers to accelerate drying.

Since moisture transmission is affected by temperature and humidity, maintain the actual service conditions for a long enough period prior to installing (the floor covering).”

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This is a very appropriate recommendation to make to any builder or homeowner and should also be considered when discussing the timing of wall treatments, such as interior insulation, dry wall or other coverings.

Joe Lstiburek of the Building Science Corporation (www.buildingscience.com) is a leading researcher and author on issues of building performance. Moisture in foundations has been a significant topic for his efforts over the past couple of decades, largely due to the prevalence of mold in recent years. In 2002, the Building Science Corporation released their report 0202 on Basement Insulation Systems to give proper guidance to the timing and design for insulating basements. The report states: “Thousands of pounds of water are contained in freshly placed concrete in basement foundation walls; drying in uninsulated exposed walls takes many

months, longer in walls with impermeable insulation systems.�

The fact remains that moisture is a natural part, and a required part of the construction process for a high-quality concrete foundation.

However, it is essential that the homeowner understands and set proper expectations for how to handle the concrete foundation to achieve the best quality home possible. This includes dehumidification, time or both. It also means that builders must be aware of the air movement in a foundation space to facilitate active movement of air to help remove the excess moisture from the concrete as well as preventing the build-up of moisture in dead air spaces.

Moisture leaving the concrete naturally will raise the relative humidity of the air adjacent to the concrete surface. Concrete, by nature, lags significantly in its temperature change from warm to cool or cool to warm. With such a

temperature lag, the rapid change in relative humidity will result in condensation on the concrete surfaces if sufficient air movement or active dehumidification is not present to lower the amount of moisture in the space. This is increasingly important as construction moves toward completion and the home becomes tighter and tighter.

Want to know more? Contact CFA Managing Director, Jim Baty at 866-232-9255 or by email at jbaty@ cfawalls.org. The CFA is a national association for professionals with the mission to support the cast-in-place contractor as the voice and recognized authority for the residential concrete industry. ACI 332 is the Residential Concrete committee for the American Concrete Institute and as a code committee is seeking professionals from all aspects of this industry with an interest in participating in the development of expanding and strengthening this concrete code.

www.forconstructionpros.com/concrete | December 2014 | Concrete Contractor

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The Secrets to Specifying

Bonded Abrasive Polished Concrete for New Construction

44 Concrete Contractor | December 2014 | www.forconstructionpros.com/concrete

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Proper sub-grade slab finishing will help prevent cracking which leads to a more aesthetically pleasing finish.

Photo Credit: Jim Cuviello

Currently the most widely used and accepted specification used by specifiers is by the Concrete Polishing Association of America (CPAA). The CPAA specification should be used to fill in the specification sections not talked about in this article. Polished concrete can be broken down into the manufacturing of the substrate to be polished and the processes used to polish the substrate. What factors need to be considered and controlled?

Producing the substrate to be polished

Why polished concrete installations go wrong and why specifications by themselves aren’t enough for success.

P

olished concrete is manufactured on site. While other flooring is manufactured in a factory, the result is a product with consistency and known characteristics such as durability, wear ability, stain resistance, etc.

So, how is polished concrete “manufactured” on site where there are tight time constraints and multiple trades in the same area while the manufacturing process is taking place? What can’t be addressed in specification’s that is needed for a successful installation?

Any substrate can be put through a process of polishing but the substrate must be conducive to the polishing processes. Manufacturing of the substrate is as critical as the process used to manufacture the polished finish.

The following points are considerations required to produce a substrate that is easy to place and finish. Proper placement and finishing reduces the chance of delamination and shrinkage to reduce cracking, curling and produces tight consolidation and maximum durability enhanced by the mechanical polishing process. Many of these considerations are dependent on the geographical location and available materials needed to produce the substrate. (Note: For additional considerations to be placed in the Division 3 specification, refer to the CPAA recommendations on their web site.)

1. Sub surface requirements – slab on grade and deck a. Preparation of the sub grade (reduces cracking) b. Vapor barrier (type ASTM E1745 – 09, installation ASTM E1643 – 09) c. Reinforcement d. Bulkheads e. Forms that create aesthetically pleasing construction joints and proper edge finishing

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Pictured here is a not so nice looking pour back.

Photo Credit: Jim Cuviello

f. Penetration finishing that creates an aesthetically pleasing finish 2. Concrete a. Raw materials – cement (ASTM C150 – 09), water, aggregates (quality and properly gradated sand and course aggregates) Raw materials must be from the same batch and source to avoid variations in color. b. Admixtures – plasticizers, retarders, accelerators can cause random variations in set times resulting in inconsistencies when finishing. Air entraining is not recommended by ACI for interior hard troweled surfaces

and can cause micro voids in the polished finish. When admixtures are “not understood” by finishers delamination and other problems can occur. c. Supplementary materials – fly ash, slag, fume – the total volume should not exceed 20 percent of cement volume and if possible avoid. d. Integral color – also considered an admixture. If used, the cement fine layer needs to be removed, exposing sand aggregate to reveal the true color.

Troweling and surface consolidation create different shades of color.

Pictured here is a good looking pour back.

Photo Credit: Jim Cuviello

e. Mix design – the combination of raw materials and supplementary materials. The concrete mix design must be one that allows for ideal finishability. f. Batching and Mixing – to maintain consistency of the substrate being manufactured.

3. Placement of slab body, edges, penetrations and pour backs a. Craftsmanship of the finisher and experience b. Placing – perform smaller pours to prevent concrete from getting away from finishers and allow attention to detail c. Consolidation – ensures a substrate with a tight structure around aggregates d. Surface finishing – effects reflective clarity, color and durability of the polished surface. To be performed by knowledgeable finishers to avoid delamination, spalling, over watering of the surface and washing out of cement fines around penetrations and edges.

Tight consolidation of the surface around penetrations and edges should also be performed.

Raw materials must be from the same batch and source to avoid variations in color.

Photo Credit: Jim Cuviello

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One part of a substrate protection plan is to protect the substrate to be polished. Other trade specifications could cause damage to the slab during the installation of their material.

Photo Credit: Jim Cuviello

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e. Flatness – The greater the Floor Flatness (FF) the less wavy the polish will look. f. Construction and control joint placement means, methods, material and spacing to achieve aesthetically pleasing joints.

4. Curing – To prevent the effects of moisture loss to avoid shadowing created by uneven hydration, surface crazing, delamination and cracking. a. Water b. Compound c. Environmental conditions (Note: The structural plans used by the cast-in-place contractor should include a graphic delineation showing the limits of the polished concrete to add emphasis to the placing/finishing contractor to pay extra attention to the polished concrete requirements during bidding and construction.) The cast-in-place and polishing specification need to refer to one another by listing each in the RELATED SECTION of each specification.

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1. Protection before polishing a. Stain prevention – Diaper all equipment. No pipe cutting. Temporarily protect the surface during steel erection, masonry, drywall and painting operations. b. Construction traffic - No parking of vehicles or lifts, use non-marking tires. c. Construction material staging on slab – Do not store materials on slab. d. Hydration shadowing/moisture retention – Other than the proper means for curing do not cover the slab with any protection that traps moisture until all unused moisture required

48 Concrete Contractor | December 2014 | www.forconstructionpros.com/concrete

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Concrete polishing specifications must be a balance between prescriptive and performance characteristics.

A prescriptive specification details step-by-step how the polished finish is to be produced.

Unless the concrete substrate is reproduced exactly from one job to the next (polished with the same make and model of equipment; the equipment is moved across the

surface at the same speed with the same rotational speed of the abrasives; the same weight of the equipment; the same diamond abrasives; the same number of abrasives used under the equipment, etc. is specified) a prescriptive specification will not work on every job. Prescriptive specifications do as much harm to the industry as shoddy workmanship. Each job is different based on

The greater the Floor Flatness (FF) the less wavy the polish will look.

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for hydration has left the slab to avoid shadowing caused by uneven hydration. Protection must be removed at the end of every day. No protection should be used in any manner for 28 days. Do not allow moisture to get trapped under protection when used after 28 days.

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The second component in manufacturing a polished concrete floor is producing the polish. The CPAA has defined three methods for producing a polished surface – Bonded Abrasive, Burnished and Hybrid Polished Concrete. Although not considered polished by the CPAA, Surface Coated Concrete does create a shiny surface. Each of these has its advantages, disadvantage and place in the industry. (Note: Refer to the CPAA position papers in the specification section of the CPAA web site for a full understanding of each category.)

Bonded Abrasive Polished Concrete, as defined by the CPAA is the most specified type of polished concrete and is what the polished concrete industry is originally based on.

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Other than the proper means for curing do not cover the slab with any protection that traps moisture until all unused moisture required for hydration has left the slab to avoid shadowing caused by uneven hydration.

Photo Credit: Jim Cuviello

the substrate, job site conditions and logistical requirements.

Contractors who polish concrete own equipment from different manufacturers with different characteristics and purchase abrasives that also have different characteristics and quality.

The polishing process has to be performed taking into many variables which will be different on each job.

A performance specification says it doesn’t matter how you produce the finished result as long as you meet specified measurable results. This is also a dangerous proposition for the industry since contractors often learn how to trick the means for measuring the surface finish.

When a combination of prescriptive and performance specifications are used you are able to specify more clearly what measurable finish is expected and the means required to produce the finish.

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50 Concrete Contractor | December 2014 | www.forconstructionpros.com/concrete

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steps will provide the best results the substrate will allow. The prescriptive factors are simple but effective.

The prescriptive factors

1. Use bonded abrasives from X manufacturer that have a history of producing the best results the substrate will allow. It is not the densifier that creates the polish, it is the mechanical interaction between the abrasives and substrate.

Why would a specific densifier be specified and required in the submittal process but not abrasives?

2. Follow a sequence that follows a traditional sequential grit process, which does not skip grits and drops back one grit size when transitioning from metal bond abrasive to resin. If an abrasive manufacturers’ predetermined process is known to produce the same finish when compared to a traditional processes it would be acceptable.

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Yes, I know, “The industry has progressed and there are transitional abrasives.”

“If transitional abrasives are used, comparison testing in several areas of the slab must be performed to determine if the transitional abrasives are providing the same if not better results than if you drop back one grit size when progressing from metal to resin bond abrasives.”

This is where the performance side of the specification takes over. If a contractor can meet the performance requirements “through the use of bonded diamond abrasives” then it is at the discretion of the contractor on how they meet those requirements. Would it surprise you to know there was a time when a 600 grit was part of the process? Yes, the use of a 600 grit can make a significant difference.

3. Fully refine each abrasive to its

maximum potential as defined by the CPAA. 4. Make sequential passes with each pass perpendicular to the previous pass.

5. Thoroughly clean the floor after each grit, removing debris larger than what the next grit size will produce.

6. Apply the densifier to the point of rejection and keep the surface saturated for 30 to 45 minutes.

Apply the densifier based on porosity and environmental conditions. Re-apply to rejection and/or thin form later in the process as needed.

7. Apply semi impregnating microfilming or impregnating protection as defined by the CPAA. 8. Installer qualifications must be met as defined in the CPAA 03 3543 specification.

The specification must state the visual degree of cut (cream/cement fine, salt and pepper/sand aggregate

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52 Concrete Contractor | December 2014 | www.forconstructionpros.com/concrete

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What a general contractor needs to consider for proper scheduling of the project 1. Polished concrete installation to occur: a. After 28 days of placement. b. The building is enclosed. c. Before interior walls are constructed is preferred, next would be after the studs are placed but before or after drywall installation, then after drywall but before the final paint and mill work.

The later in the project the polished concrete is installed the higher the price and the greater the chance there is for problems. Installers not proficient in edge finishing will leave edges not finished to the same degree the main body the floor is and/or leave scratches. d. When there is adequate lighting for polishing processes. e. Understand the time requirements for the installation processes.

or a degree of course aggregate) and the degree of polish (flat/ground, satin/honed, semi-polished or highly polished). (Note: The CPAA has a position paper that defines each of these in detail and the quantifying criteria for each.)

Other visual characteristics that need to be defined in the specification and finish plan are color, decorative cuts and joint fill.

Protection after polishing should be a type that will withstand remaining construction to be performed after the floors have been polished. The polishing contractor should be required, prior to turn over to the owner, to return to perform a final clean and burnishing of the surface as well as maintenance training of the owners floor care staff.

Starting and finishing abrasive grits should not be specified to achieve the degree of cut (cream/ cement fine, salt and pepper/sand

aggregate and course aggregate) or finished gloss. The concrete, machine weight, rotational movement and speed, forward liner pace, abrasive type, bonding and contact area to the surface will determine starting and finishing grits. This is another facet of the process that can be met through the combination of a prescriptive and performance specification.

Why do polished concrete installations fail?

When manufacturing other flooring in a factory, all components are controlled by one company. When manufacturing a polished concrete floor on site there are often six or more independent companies involved in the manufacturing process and countless other companies working on top of and around the “onsite factory.” As a result, specifications and plans can only go so far to ensure a successful polished concrete installation.

Specifications start with the architect properly writing them. To do this, the architect must take the time to understand the total process which includes the manufacturing of the slab and polishing. Each project requires customized specifications, do not copy and paste. The qualification section must require confirmable past performance of jobs as the same size and scope.

Submittals must then require the qualification information be submitted as part of the submittal package. There’s a disconnect in many specifications where qualifications of the subcontractor are stated but this information is not required in the submittals. When qualifications are listed to be submitted, rarely is the information asked for and when it is, rarely is it checked. The use of specifications starts with the estimator and the estimator confirming and only taking bids from sub-contractors who meet the qualifications portion of the specification.

Specifications are only as good as the general contractor and sub-contractors relied upon to understand them and follow them. Installations

require increased and equal craftsmanship by all trades involved.

One trade should not be expected to make up for the short comings of another trade.

The architect and owner must hold the general contractor accountable. Let me say it one more time, the architect and owner must hold the general contractor accountable.

The general contractor must hold the sub-contractors accountable.

A polished concrete installation goes beyond specifications for there to be total success. Specifications alone will not result in a successful polished concrete installation.

It is the responsibility of the architect and owner to have a reasonable expectation of what a polished concrete floor is. They must understand the floor is being manufactured on site and when finished it will not be perfect, there will be imperfections inherent with all concrete, it will be consistently inconsistent. They need to understand variables during finishing such as wind, the angle of the sun, humidity, and temperature will affect the finished surface and most often this becomes too hard to control.

What an owner will get is a floor that can help achieve many LEED points, be aesthetically pleasing, highly durable and extremely low maintenance. A decision to use

Outside of specifications a polishing contractor needs to know the following to be able to properly price the work • Timing of installation – before walls, after walls, etc.

• Will power be provided?

• Will a dumpster be supplied for dust/slurry disposal?

• Will water be provided?

• How many square feet will be provided to the concrete polisher at one time and how quickly will the following areas be provided and number of days in the schedule to complete each section?

54 Concrete Contractor | December 2014 | www.forconstructionpros.com/concrete

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The general contractor will also want to • Note in all other trades scopes of work and in their instructions to bidders, that the project will have exposed polished concrete as the finished floor. This sub is responsible for protecting these areas from damage resulting from the work they perform. Include the substrate protection section from this article.

• Constantly remind and enforce during progress meetings and on site that they are working over a finished floor.

• Bid the cast-in place package separate from the polishing. When the two are combined critical information for the success of the installation is lost when communication from the polisher to the general contractor is required.

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polished concrete should not be based on pretty pictures from the Internet or brochures, but based on site visits to other buildings like the one being constructed.

If a general contractor does not take the time to understand the process and commit to the process, the polished concrete project will be a failure. The general contractor is responsible for coordinating all trades involved in making the polished concrete project a success. They are the ones who have to ensure specifications are followed and the requirements of the specifications are met. Not only do they need to understand the processes, they need to understand the jobsite and polished concrete contractor’s requirements for installation. Polished concrete is installed differently than other finishes. Polished concrete is installed during major construction and not at the end when other finishes are installed. It is also the general contractor’s responsibility to understand what the architect and owner’s expectation is. The general contractor is the one responsible for monitoring and qualifying the finished work. Too often does a general contractor not take the time to understand these expectations and the result is a polishing contractor having to deal with the general contractor’s expectation and opinions which are most often different from the architect and owner.

General contractors and sub-contractors need to know while they are bidding the project there is extra coordination required between multiple trades and companies in the manufacturing of the final floor finish that will happen during major construction.

For some of the other trades this will mean nothing more than they will be required to place and remove protection daily and extra trade coordination will be required that can effect progression through the project.

The cast-in-place and polishing subcontractors

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need to know there will be extra focus and emphasis required to make sure specifications are met. Often to ensure quality, pours need to be made on a smaller scale and extra workers are required to ensure detailed quality. Extra time will be required by the general contractor to monitor the other trades on site to ensure they do not damage the concrete to be polished. Polished concrete requires large areas to be free and clear of all materials and trades when polished. The process is slow and produces a lot of mess. This is not all of the considerations but some of the many a general contractor needs to be aware of. If they are not aware of the requirements, they often do not learn about them until after schedules have been made. (See side bar on page 52) General contractors don’t like unexpected surprises.

Often the requirements for the polished concrete manufacturing processes are not realized until after the polishing has been awarded to a concrete polisher and pre pour meetings take place. The result is a general contractor project team who become unwilling to rearrange schedules, take the time to fully grasp the polished concrete installation and its total requirements.

The result is a failed polished concrete installation.

To ensure the general contractor embraces the success of the polished concrete installation they must be made aware of the requirements that are means and methods related and not put into specifications.

The best way to do this is in the summary section of Division 1. Fully make the general contractor, cast-in-place, polishing contractor and all other trades aware of the emphasis that will be placed on the polished concrete finish. Let them know now is the time to fully understand the specifications, the architect’s expectations, time requirements and other considerations required for a successful installation.

The general contractor and sub-contractors must understand the cast-in place and polishing specification to be followed and any deficiencies will become a liability to them. All other trades must be alerted of the additional requirements that maybe placed on them during the manufacturing processes and specifically what they can and cannot do over the substrate to be polished.

The concrete polishing trade has to take responsibility for its own level of craftsmanship. Asking the cast-inplace finishing trade to perform at a higher level so the polishing industry can use lower skilled polishers is irresponsible. Both trades require craftsmanship and both trades pull from the same quality of labor. It takes all parties to perform at a higher level.

A polished concrete installation requires realistic expectations, understanding of the process, held specifications of all trades and an effort on the part of everyone involved for success. For the polished concrete project to be successful both the concrete placer/finisher and polisher must perform their

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The performance factors It is the opinion of many within and outside the polished concrete industry that the current industry standards and means for quantifying surface finish using surface profile at best can be used as a general guide. The current means for surface profile quantification do not provide conclusive information to the surface finish. Currently the CPAA specifies Reflective Clarity Readings per ASTM D5767 and Reflective Sheen Readings per ASTM D523. Both of these standards are accepted by the concrete polishing industry. Better methods for quantifying the finished surface are currently being researched and developed.

Polished concrete is not for all areas and should be specified to be used in areas appropriate for polished concrete.

Polished concrete should not be used in areas exposed to acidic conditions such as bathroom, battery storage areas,

certain food areas, commercial kitchens, etc.

The next step

It is known that the smoother a surface is, the greater the wear resistance. But what does this really mean? A material will start out with an abrasion resistance of X. When refined and polished that resistance to abrasion will increase over its original state. You can have a very dense material that can be polished which provides a crystal clear reflection but wears very quickly because the material is soft. The most important quantification of the polished concrete surface that no one talks about needs to be the durability of the finished surface based on the substrate that was polished. Gloss and profile readings only give you guidance of how well the surface was refined, they don’t tell you anything about the durability of the polished substrate.

scope with craftsmanship.

A successful installation is a group effort and goes beyond specifications. The result is a floor that can help achieve many LEED points, aesthetically pleasing, highly durable and extremely low maintenance.

Ed. Note: Jim Cuviello is the owner of Cuviello Concrete and has been in the industry for 12 years. He is a founding member of the Concrete Polishing Association of America. He can be reached at jim@cuvielloconcrete.com, www.cuvielloconcrete.com For a copy of the CPAA specification visit their web site www. concretepolishingassociation. com.

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