Concrete Contractor December 2015

SPECIAL SECTION: Spotlight on Decorative Concrete

20 December 2015

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Building a VELODROME 10 ACI 562: Rethinking Concrete Repair 34

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December 2015 | Issue 7, Volume 15

WHAT’S INSIDE Departments 4 Editor’s Letter 6 Challenging the System 8 Legal Matters 48 Foundations Q&A 58 The Last Placement

SPECIAL SECTION: SPOTLIGHT ON DECORATIVE CONCRETE

Cover Story

Cover Photo Credit: Jenny Eichholz

50 Polished Concrete Floors Offer Significant Savings

Owners of the Liberty Center chose to install polished concrete floors in lieu of ceramic tile, saving the owner over $1 million dollars on the overall project budget.

Features

46 ICPSC Returns to World of Concrete 2016

10 Building A Velodrome How to place concrete on highslope projects.

Make plans to attend the International Concrete Polishing and Staining Conference in conjunction with World of Concrete.

20 GRFC Offers New Design Options for Concrete Countertops With the introduction of GFRC into the marketplace over the past several years, contractors and specialty precast shops have taken to this new style of concrete construction.

24 Finishing Techniques for Concrete Countertops As one of the few building materials created from raw ingredients, concrete is a fantastic material to design and work.

28 The Science of Color

34 Rethinking Concrete Repair A new guide helps concrete professionals interpret performance-based code requirements.

40 Product Focus: Concrete Attachments A compilation of concrete attachment products.

44 World of Concrete Product Showcase A compilation of products from exhibiting companies at World of Concrete 2016.

56 How to Properly Maintain Your Grinder Your grinder is a capital investment, and it is important to get the best ROI from it. Learn how with these tips.

What’s Online

Concrete is a material that varies in many ways, so achieving a perfect color is as much an art as it is science.

32 Finding Success in Artisan Concrete What are the tools needed for a contractor to find success in artisan concrete work?

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

Continuous 29-hour Concrete Pour Largest in Wisconsin History Four Putzmeister truck-mounted boom pumps, 50 ready-mix trucks and more than 250 construction workers place 9,200 cu. yd. of concrete over 29-hour period.

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Waterproof Membranes Help Maintain Critical Road, Rail and Bridge Infrastructure A guide to newer, proven, high-performance spray-applied waterproofing technologies to protect concrete and steel infrastructure Search: 12121060

www.forconstructionpros.com/concrete | December 2015 | Concrete Contractor 3

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EDITOR’S LETTER

Spotlight on Decorative Concrete

O

ne of my favorite parts of my job is the opportunity to meet our readers. I’m always excited to meet new contractors and catch-up with contractors I’ve previously met.

Based on my conversations at various industry events this fall, contractors tell me they’ve been busy.

So much so, several contractors reported to have turned away work and better yet, booked projects well into 2016. It’s a good feeling to know that the work is plentiful and contractors are reaping the benefits. If this is any indication for what to expect in 2016, my crystal ball tells me contractors will have an equally busy and successful 2016.

The December issue of Concrete Contractor is our annual Spotlight on Decorative Concrete issue. In this special section, we’ve compiled a series of articles which examine the latest developments in decorative concrete, specifically the continued and growing interest in concrete countertops.

We also highlight the latest finishing techniques you may want to employ if you’re taking on this type of job.

Have you ever wondered why your decorative concrete job displayed a color that wasn’t what you were expecting? Gain a better understanding about the materials you use to apply color with an examination Facebook.com/ ConcreteContractor

Advisory Board

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

behind the science of color and the role it plays when applied to a concrete surface.

As contractors continue to look at ways to diversify their business and become profitable, we wrap up the section with a look at what it takes to be an artisan concrete contractor.

Our cover story this month features a massive, 100,000+ square foot polished concrete job at a mall in Ohio. Not only was the size and scope of this project a huge undertaking for the contractors involved, but it also demonstrates the value proposition of polished concrete floors.

If you’re a polished concrete contractor, I would encourage you to consider registering for the International Concrete Polishing and Staining Conference (ICPSC), to be held February 1, 2016 in conjunction with the World of Concrete. Turn to page 46 to learn more.

Finally, as 2015 comes to a close, we hope you look back at your successes of the year and look ahead to your prosperity in 2016. See you next year.

Follow us @ Concreteinsider

Kim Basham KB Engineering Cheyenne, Wyo.

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

Jim Baty Concrete Foundations Association Mt. Vernon, Iowa

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

Search: Concrete Polishing

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

Joe Reardon SASE Orlando, Fla.

4 Concrete Contractor | December 2015 | www.forconstructionpros.com/concrete

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T C E J O R P A T O G E V ’ YOU

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.

SAKRETE® is a registered trademark of Oldcastle.

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CHALLENGING THE SYSTEM

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

Understanding ACI 117 Tolerance Language

Bruce A. Suprenant, PE, PhD, FACI, is technical director for the American Society of Concrete Contractors.

Reach him at bsuprenant@ bsuprenant.com.

Making a Challenging Task Easier with Graphics

W

e hear this question often: “I have a beam and a column, what ACI 117 tolerances apply where?” The caller hangs up after an hour long conversation and we wonder how much we have helped. To make it easier to discuss, we developed a graphical approach using an elevation and plan view of a beam and column similar to what callers see on the construction drawings.

Without any tolerance values, we have shown where the tolerances apply. Once the caller sees where they apply, the tolerance values are found in Chapter 4 of ACI 11710 “Standard Specifications for Tolerances for Concrete Materials and Construction”. We hope this graphical presentation helps the readers make a challenging task much easier.

In this view, beams, girders and slabs (floors) are the horizontal structural members, while columns and walls are the vertical members.

In this view, local formed surface control sets tolerances for abrupt (fins and offsets) and gradual irregularities (such as form bulging). Local unformed surface control sets tolerances for floor flatness and levelness.

6 Concrete Contractor | December 2015 | www.forconstructionpros.com/concrete

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Note in this view that overall elevation applies to both the formed (bottom) and unformed (top) surfaces of a floor slab, but the tolerance differs from the tolerances for flatness and levelness.

These are sometimes confused with each other.

For columns and walls, the overall vertical control is a combination of location tolerances and tolerances on variations in verticality. The tolerance on overall elevation control applies to the top surface of the wall or column, and the local formed surface control applies to formed column or wall surfaces.

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www.forconstructionpros.com/concrete | December 2015 | Concrete Contractor 7

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LEGAL MATTERS

By David Whitlock

Hiring Keepers

It’s more important than ever for contractors to be careful about their hiring practices.

G

iven today’s labor pool, you need to do more recruiting. It may be time to delegate this to someone who will focus on this, as that may free you up to manage your business better. You do not have to hire a full time HR person, but you might want to delegate recruiting functions to an Office Manager or other staff in your office.

THE APPLICATION As a practical matter, for field labor you can probably use an abbreviated hiring process. You should use a good employment application. A good application will ask the questions and get the answers you really need, e.g., education, experience,

basic background information, references, etc. You may decide you do not need education information, but it is probably cheaper to use a comprehensive application and just tell field labor candidates which sections to complete. You definitely want prior employment history and reference information.

A good application will also have important legal information that you want the applicant to know. This is an “at-will” employment. There will be a background check, drug test, credit check, and/or motor vehicle record check. Lying on the application or hiding material information will result in termination. An arbitration agreement or jury waiver provision applies to any disputes. Finally, include required legal disclaimers such as “Equal Employment Opportunity Employer.”

Always analyze the completed application carefully. Look for gaps in employment. Look for a progression of diminishing responsibilities or pay. Look for vague, unspecified reasons for leaving a job. Be wary of

these classic reasons: • “Disagreed with policy” (= fired for rules violation.)

• “Personality conflict” (= couldn’t get along with co-workers, supervisor, or customers.)

• “Poor working conditions” (= fired for poor performance.)

• “Mutual agreement” (= fired.)

• Look for incomplete or blank responses.

If your application asks about criminal convictions (it should), and the applicant doesn’t answer, then guess what that means?

There is probably a gap in employment in there too.

THE INTERVIEW Interview candidates carefully.

Do this in private where you won’t be interrupted. Ask open-ended questions that get the applicant to talk, and follow the 80/20 rule: let the applicant talk 80 percent of the time. Ask about likes and dislikes with respect to current or former job

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duties, supervisors/managers, companies, customers, etc. If you are recruiting students or persons new to the workforce, they may not have a former manager or supervisor. Ask them instead to talk about likes and dislikes with sports or academics.

You will get nearly the same information and “feel” about the applicant.

Spend 20 percent of the time “selling” your company and the job.

You want the candidates you don’t select to say good things about your company too, especially in these harder hiring times.

Although hiring field labor through a shortened process suggests you might not check references, it is still a good idea. Don’t get stone-walled by a response limited to job title and dates of employment. At least ask if the candidate is eligible for re-hire. Again, with persons new to the workforce, you may not have prior employment references to check. Therefore, you might want to talk to the applicant’s personal references. Talk to the applicant’s coaches or teachers about motivation, attention to detail, willingness to work hard, etc.

Finally, give the new hire a proper welcome and orientation. Let the new hire meet the “boss” early in the orientation process, and make all levels of management part of the orientation process. This helps the new hire feel truly welcome and sets the stage for good communication later.

SAFETY TRAINING Most important, especially for workers new to this kind of work, is safety training. Make certain you train new workers carefully in safe work practices, as you do not want them to risk injury or damage. This is especially important for younger workers you are recruiting from a local school. Improper safety habits can not only hurt your current workers, but it can also jeopardize your source of recruits in the future.

With luck, following these suggestions will improve the quality of your recruits and help them stay with you longer.

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

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www.forconstructionpros.com/concrete | December 2015 | Concrete Contractor 9

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FLATWORK / SLABS

By Joe Nasvik

Building A VELODROME

How to place concrete on high-slope projects.

PROJECT PARTICIPANTS Owner: Kenosha Wisconsin Park District General Contractor: Rasch Construction & Engineering, Kenosha, Wisconsin Layout and Engineering: Clark Dietz, Inc., Kenosha, Wisconsin Excavation and Grade Preparation: DK Contractors, Kenosha, Wisconsin Concrete Conveyor: Potratz Concrete Conveyor, Milwaukee, Wisconsin Ready-mix Producer: Gleason Ready Mix, Kenosha, Wisconsin

T

he Kenosha Park District in Wisconsin is rebuilding its velodrome, a track arena dedicated to bicycle racing. The track has two straight sections and two 180-degree high pitched circular bends. It’s one of the oldest tracks in the U.S., starting in 1927.

The old track was constructed with asphalt and had fallen into disrepair but because of the

continuing popularity in the Kenosha area, the Park District decided it was time to replace the old asphalt track with a new concrete one. It would have even steeper angles going around the curves. But as you might imagine, there are many construction challenges when taking on a project like this. Challenges included layout, excavation, fine grading and compacting subgrade, forming, placing and finishing concrete, and cutting control joints.

At the banked turns the horizontal width of the track is 21 feet, three inches, the vertical rise is 11 feet, three inches and the maximum angle of rise is approximately 30 degrees— approximately a 53 percent slope. The vertical height of the curves on the new track will be two feet higher than the old one in order to meet present qualifications for national competition.

DECIDING TO BID Larry Rasch, the CEO of Rasch Construction and Engineering, Kenosha, Wisconsin, says his background is structural engineering.

His company specializes in small to medium sized building construction, industrial projects, public works projects for the state of Wisconsin, McDonald’s store renovations, and

Placing pavement on steep slopes is challenging—estimating is more difficult, concrete mixes must be low slump, more labor is needed, equipment needs are different, and finishing is more complicated.

Photo Credit: Joe Nasvik

historic restorations. “We are an old line GC willing to consider a wide range of projects,” he says. So when the velodrome project came out for bid he thought it looked interesting and liked the idea of the challenges it presented.

PREPARATION AND EXCAVATION The existing track consisted of several layers of asphalt so the first step involved removal.

Rasch said they ground it up for reuse as compactible fill for the reconstruction. Due to the steep slopes at either end of the track, trackhoes were employed for the work. Wheel-loaders were used for the flat center portions of the track.

Rasch hired surveyors to do the layout work. They set points on stakes and supplied service to the trackhoe, which had GPS capabilities—so steep grading was accomplished using GPS with support from the survey team.

10 Concrete Contractor | December 2015 | www.forconstructionpros.com/concrete

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FLATWORK / SLABS Following excavation and fine grading Rasch crews set concrete forms top and bottom but as the job progressed the excavator persuaded them to set forms before he fine graded—an additional way to check for accuracy.

Compacting subgrade on the straight sections of the track was accomplished by standard rolling vibratory compactors but on the curved embankments, the trackhoe used a vibratory compactor attachment. “We always checked the grade for flatness and measured compaction before concrete placement,” Rasch added.

PURCHASING A ROLLER SCREED Though his company had never used one, Rasch realized that striking off concrete for a project like this would best be accomplished by using a roller screed. He says he searched the Internet for manufacturers and ended up deciding to

purchase a Lura Screed.

He added that a selling point was the company’s willingness to visit the jobsite on the first concrete placement to help train the crew. Placing concrete using a roller screed turned out to be more productive than they had predicted.

There are several things to keep in mind when purchasing a roller screed; tube length requirements are different from project to project so you should ask the manufacturer how they change lengths to fit job requirements. Screed tubes should be straight enough to meet your requirements for flatness.

Ask to know what the manufacturer guarantees—pavement flatness is both an equipment and application issue.

Dennis Lura, the founder and president of Lura Enterprises, West Fargo, North Dakota, says the width

Working with low-slump concrete requires more placing labor. The conveyor operator (shown in background) plays a role too. He helps ensure that concrete is evenly distributed.

Photo Credit: Joe Nasvik

between forms for this project was 23 feet. “It’s best for the roller or tube to be a foot longer on both sides than the placement so workers have some latitude in terms of sideways movement while they are screeding,”

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12 Concrete Contractor | December 2015 | www.forconstructionpros.com/concrete

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he says. “So we sold them a 20 foot and a four foot tube that screwed together for this project.”

Lura says they produce tubes and threaded ends that meet ± 0.017 of an inch straightness requirements on a 20 foot long tube. He adds that all long screeds; wood, aluminum or steel—rectangular or cylindrical—typically deflect upwards on the first pass in the center region of the placement and then remove concrete from below the flatness plane on the second and

succeeding passes. So workers should be careful about how many times they pass over an area.

PLACING CONCRETE Rasch says there was nothing exotic about the concrete mix for this project. It was a 4,000 psi air-entrained mix that included micro-fibers.

The original thought was to place concrete with a two inch slump but they quickly learned it wasn’t workable.

So they used three inch slump mixes, The worker second from the left uses a shoulder harness to hold the roller screed in position, preventing it from sliding down the slope.

Photo Credit: Joe Nasvik

WHAT’S A VELODROME? Velodromes are arenas for bike racing and are found the world over. Velodrome racing is a summer Olympic Sport. Tracks are constructed as both inside and outside venues and are made from timber, synthetics, asphalt, concrete, and even cinders.

Bicycles that race in velodromes have gears, no brakes, and no free-wheeling pedals. If you want to stop or slow down you push back against the pedals. The banked turns at either end of the track allow bikes to be roughly perpendicular to the surface of the track, allowing speeds that can exceed 53 mph. Minimum speeds are also necessary to keep bikes from falling over on turns.

There are approximately fifty velodrome tracks in the U.S. and the Kenosha track is believed to be the oldest outdoor one.

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www.forconstructionpros.com/concrete | December 2015 | Concrete Contractor 13

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FLATWORK / SLABS concrete that still didn’t slump or move after placement.

Workers used a truck-mounted telescopic-belt conveyor to place concrete. It’s an ideal application because it can place low-slump concrete wherever it’s needed quickly and easily.

To operate the screed required a worker on either end of the placement plus an additional person wearing a shoulder harness on the top end of the screed to pull upward on the screed preventing it from slipping downhill.

Workers needed to pay special attention to the location of the screed when they worked on the curves. The screed needed to be parallel to the radial line of the curve to achieve the best 3D profile.

NUMBERS AT A GLANCE work the bull float in the horizontal direction—one worker operated the float while the other pulled on a rope tied to the float from above to prevent it from sliding down the slope. To finish the work a broom was passed perpendicular to the line of bike travel to achieve a coarse finish.

CONTROL JOINTS The owner and contractor decided to saw radial contraction joints in the five inch thick pavement every 10 feet, measuring 10 foot widths at the midpoint of each curved panel. They also decided not to cut horizontal joints in the middle of the panels fearing that bike tires could be caught in the cut lines. Hand-held diamond saws were used to cut the joints.

FINISHING

PROJECT COMPLETION

After the screed passed over the fresh concrete, workers passed a bull float over the surface in both directions. Rasch said he didn’t anticipate the need for two men to

The project started in May 2015 and the work was finished in midNovember. The last phase of the concrete work consisted of placing an

Track Length: 1,083 feet at the bottom of the track and 3,200 feet at the top of the track Track Width: 23 feet Max Elevation Rise: 11 feet, 3 inches Max Angle: 30 degrees Max percent grade: 53% Concrete thickness: 5 inches Cubic Yards Concrete: 600 cubic yards eight foot wide flat pavement around the inside of the track so that bikers could safely enter and exit the track.

After completing the velodrome with such steep pavement grades, Rasch says he has a new confidence about doing sloped pavement projects.

The new track is state-of-the-art and the Kenosha Park District has a new national presence. Bike racing at the new arena will begin in the spring of 2016.

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The Power to Build

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Wherever your next job takes you, we are ready with the product solutions to give you the power to build. Call your local rep at (800) 999-5099 and connect with us on strongtie.com/anchors.

Š2015 Simpson

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Strong-Tie Company Inc. ICIBUILD15

1/6/16 2:27 PM

SPECIFICATION GUIDE: DUST EXTRACTION

Dust Extraction

A compilation of technical information when choosing your next dust extractor.

1 Pulse-Bac HPLM 3690

Pulse-Bac has introduced another new concept to the world of dust collection with their new line of HPLM (High Performance Low Mass) vacuums. What is HPLM? Put simply, they’re vacuums designed to have the highest power to weight ratio available. This new line of vacuums delivers very high suction while working on a light weight platform that is designed to be easily transported. The 3690, the first unit to be released in the line, delivers 690 CFM with 110” of water lift and weighs in at only 208 lbs., by comparison, that’s about 70 percent lighter than most vacuums with similar suction power.

ForConstructionPros.com/12109625 World of Concrete 2016 Booth #S10853 Model

Dimensions (LxWxH)

Weight (lbs)

Power Output (hp)

Voltage

Phases

Air Flow (cfm)

Max vacuum (psi)

HPLM 3690

34.5” x 35” x 72”

208

N/A

220v

Single

690 cfm

110” Water Lift

Model

Dimensions “(LxWxH)

Weight (lbs)

Power Output (hp)

Voltage

Phases

Air Flow (cfm)

Max vacuum (psi)

Pulse-Bac 1000 Series

25” x 25” x 36.5

30 lbs.

N/A

110v/220v

Single

140-245 cfm

70” - 110”

2 CPS CAT-5 Extractor Vacuum

The CAT-5 Dust Extractor’s design helps you maintain focus on the job and decreases downtime.

This system’s pleated primary filter elements, with non-stick coatings, have excellent dust release to prevent filter blinding and motor overheating.

ForConstructionPros.com/12140173 World of Concrete Booth #O40737 Model

Dimensions (LxWxH)

Weight (lbs)

Power Output (hp)

Voltage

Phases

Air Flow (cfm)

Max vacuum (psi)

CPS CAT-5 Extractor Vacuum

49.5” x 22” x 65”

567 lbs.

8.5 hp

480v/ 30 amp

3

400 cfm

110” Water Lift

3 HTC 80 iD II

The HTC 80 iD II is the latest dust extractor from HTC. The 80 iD II will improve your efficiency up to 15 percent compared to a traditional solution.

ForConstructionPros.com/12140095 World of Concrete Booth #S10627 / O31133 Model

Dimensions (LxWxH)

Weight (lbs)

Power Output (hp)

Voltage

Phases

Air Flow (cfm)

Max vacuum (psi)

HTC 80 iD II

46” x 49” x 71”

573 lbs.

11.5 hp

460v

3

476 cfm

N/A

Model

Dimensions (LxWxH)

Weight (lbs)

Power Output (hp)

Voltage

Phases

Air Flow (cfm)

Max vacuum (psi)

HTC Greyline 35 D

33“ x 23“ x 62“

130 lbs.

4.7 hp

230v

Single

240 cfm

N/A

Model

Dimensions (LxWxH)

Weight (lbs)

Power Output (hp)

Voltage

Phases

Air Flow (cfm)

Max vacuum (psi)

HTC Greyline 40 D

42“ x 28“ x 74“

373 lbs.

5.5 hp

460v

3

300 cfm

N/A

16 Concrete Contractor | December 2015 | www.forconstructionpros.com/concrete

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MORE WAYS TO RULE THE ROAD Nobody offers more solutions to do tough jobs with fewer machines. Scan the code or visit Bobcat.com/Road to see all the Bobcat® attachments.

1.877.745.7813 Bobcat ® and the Bobcat logo are registered trademarks of Bobcat Company in the United States and various other countries. ©2015 Bobcat Company. All Rights Reserved. | 1273

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SPECIFICATION GUIDE: DUST EXTRACTION

4 Husqvarna DC 6000 Dust Collector

The new DC 6000 system matches the company’s Dual Drive grinding machines, the Husqvarna PG 820 and PG 680.

The Husqvarna DC 6000 will replace the DC 5500, a vacuum cleaner with a traditional two-filter system. The patented double shell cyclone technology with auomatic filter cleaning takes the DC 6000 to the next level.

ForConstructionPros.com/11447350 World of Concrete Booth #O30166 Model

Dimensions (LxWxH)

Weight (lbs)

Power Output (hp)

Voltage

Phases

Air Flow (cfm)

Max vacuum (psi)

Husqvarna DC 6000 Dust Collector

49” x 30” x 75

640 lbs.

10 hp

380v 480v

3

406 cfm

3.05 psi

5 SASE BULL 1250EBS Dust Collection System

SASE Company Inc. introduces the BULL 1250EBS Dust Collection System now with the Elongated Bag System.

The BULL 1250EBS can be used with the SASE PDG 8000, PDG 6000, and all other industry 32 inch diamond grinders.

ForConstructionPros.com/12056920 World of Concrete Booth #O40841 Model

Dimensions (LxWxH)

Weight (lbs)

Power Output (hp)

Voltage

Phases

Air Flow (cfm)

Max vacuum (psi)

SASE Bull 1250EBS

48.5” x 27.375” x 69.75”

500 lbs.

N/A

230v-460v

3

388 cfm

N/A

Model

Dimensions (LxWxH)

Weight (lbs)

Power Output (hp)

Voltage

Phases

Air Flow (cfm)

Max vacuum (psi)

SASE Bull 1250PRO

62” x 30” x 71”

696 lbs.

N/A

N/A

N/A

388 cfm

N/A

18 Concrete Contractor | December 2015 | www.forconstructionpros.com/concrete

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6 CS Unitec CS 1445 H Dust Extraction Vacuum

The Electromagnetic Pulse Cleaning System of CS Unitec’s CS 1445 HEPA vacuum maintains maximum suction by automatically shaking the filters to remove debris during operation.

ForConstructionPros.com/12140146 World of Concrete Booth #O31421 Model

Dimensions (LxWxH)

Weight (lbs)

Power Output (hp)

Voltage

Phases

Air Flow (cfm)

Max vacuum (psi)

CS 1445 H

22” x 16” x 22”

23 lbs.

1.1 hp

120v

Single

130 cfm

39 psi, 259mBar

Model

Dimensions (LxWxH)

Weight (lbs)

Power Output (hp)

Voltage

Phases

Air Flow (cfm)

Max vacuum (psi)

CS 1225

17” x 16” x 23”

23 lbs.

1.1 hp

120v

Single

130 cfm

39 psi, 259mBar

Model

Dimensions (LxWxH)

Weight (lbs)

Power Output (hp)

Voltage

Phases

Air Flow (cfm)

Max vacuum (psi)

CS 1500

23” x 17” x 25”

27 lbs.

1.1 hp

120v

Single

130 cfm

39 psi, 259mBar

Register today for ICPSC! ICPSC is a conference for polishing professionals at World of Concrete where novices come to learn, experts come to advance, and the industry joins to grow. Visit www.icpsc365.com/register to register!

www.forconstructionpros.com/concrete | December 2015 | Concrete Contractor

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19

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SPOTLIGHT ON DECORATIVE CONCRETE

GFRC Offers New Design Options for Concrete

Countertops With the introduction of GFRC into the marketplace over the past several years, contractors and specialty precast shops have taken to this new style of concrete construction.

O

By Bart Sacco ver the years, decorative concrete has taken on a large advancement and progression in style, strength, and function. In the early days concrete countertop mix designs were limited, styles were basic, however very beautiful in their simplicity. The production time of early concrete countertop fabrication used to be a fairly lengthy process. The average shop used a high-strength traditional concrete mix with low shrinkage characteristics. After the item was cast it had to cure for an extended amount of time to build enough strength for the installer to be able to move on with the next step in the process. This next step would usually be honing, polishing or sealing the piece to bring on the final luster, stain resistance, or appearance desired. In the early days with traditional methods the production delay between steps

Jake Brady, owner/ designer of Jake Brady Concrete

By Design (www.

JakeBradyConcrete. com) created this stunning concrete countertop for a kitchen.

Photo Credit: Gamma Photography

could have been up to two weeks.

With the introduction of GFRC mix designs, production time and application techniques have advanced considerably. Modern forming methods allow for a host of new design options. The main reasons for popularity with this method are due to the quick turnover in production and virtually unlimited design options. A specialty shop who is familiar with this GFRC process and technique can produce countertops, furniture, mantel pieces, fireplace surrounds, shower panels and just about any type of unique design element. The GFRC process has taken a place in the outdoor market today as well. You will see exterior wall panels, waterfalls and rock features made with this versatile process.

WHAT IS GFRC? GFRC actually stands for Glass Fiber Reinforced Concrete. The traditional GFRC process consists of a very high-strength, low shrink mix design, utilizing a polymer modifier and alkali resistant glass fiber strands. The traditional installation requires a spray on “Face Coat” and

also a “Backer Coat.” Many companies utilize the same mix design for both the face and the backer coats, however with the backer coat the glass fiber is added into the mix then applied either by hand packing or spraying (with a specialized gun) over the partially set face coat. The backer coat is consolidated after application. Once cured the piece is then demolded and moved into the next stage of processing. The GFRC process is for precast operations only so you will be building forms before casting the piece.

FORMING TECHNIQUES Forming techniques will dictate the final look and style obtained by GFRC. This is mainly due to the mix’s ability to pick up extreme detail.

The form for a GFRC project can be smooth as glass, bring on textures to simulate the look of rock or wood and can also pick up the detail of a hand carved piece of art. Custom edge work can be created in countertops by building the form out of traditional Melamine and then utilizing sculpturing clay to create a unique detail to the piece. The clay may be utilized to

20 Concrete Contractor | December 2015 | www.forconstructionpros.com/concrete

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GFRC/RPC/ECC

Admix Trinic GFRC Admix Advantages

• M ulti component powdered admixture simplifies the production of GFRC, RPC, and ECC mixes • Proven through 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

Hydration Stabilizer • Ready to use powdered initial set retarder • Makes more uniform and predictable HP/UHP concrete • Glass fiber reinforced concrete, ECC/SCC

11K Single Component GFRC Mix • Just add water and start spraying • High performance 11,000 PSI premix • Add fiber for a high performance back coat

Versa Color • Sub-micron nano-particle pigment base allows for true color perception • The highest UV stability available, for use on exterior or interior applications • Carrier options include, but not limited to, water, acetone, isopropyl alcohol, denatured alcohol, and Trinic LS Densifier

Trinic Plasticiser • 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 Advantages • Increases the early and ultimate strength of concrete with minimal effect on initial workability

Integral Color • Pure and intense colors and truest black • Almost 2,000 colors possible

• Offsets the retarding effects of high plasticiser dosages while reducing pozzolan strength lag

• Low doses save money

• Delivers excellent results in normal and cool conditions where very high next day strengths are required

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FREE classes are provided each month for your success

www.trinic.us

info@trinic.us 12/7/15 9:21 AM

SPOTLIGHT ON DECORATIVE CONCRETE create simple custom detail edging, possibly to create a sink basin with a unique shape or to create a unique one of a kind edge for the project.

These custom edges can be created very quickly with this process and your possibilities are endless.

Custom edge work can be created in countertops by building the form out of traditional Melamine and then utilizing sculpturing clay to create a unique detail to the piece. The clay may be utilized to create simple custom detail edging Photo Credit: Kingdom Products

MIX DESIGN The mix design for GFRC varies amongst the professionals who manufacture these products. Most formulations start with a fairly simple mix design utilizing equal ratios of Portland cement to finely graded crushed quartz. CSA cement is added to speed set and overall curing time. This high-strength mix is further boosted in strength with the edition of a very fine pozzalon called silica fume. The water to cement ratio is regulated and kept to a minimum with the use of a very high range super plasticizer. The final admixture needed in this formula is an acrylic

polymer. Reinforcement is developed through combination of this specialized mixed design and the use of a three-quarter inch ( ¾”) alkali resistant glass fiber. Please keep in mind an important aspect of the glass fiber edition, that this is generally not added until after the cementitious portion is mixed thoroughly. This is done to reduce the breaking down of the glass fibers into smaller pieces during the mixing process. The specialized admixtures needed for GFRC like the super plasticizer and acrylic polymers are available in both liquid and dry versions.

APPLICATION TECHNIQUE The application technique is fairly straightforward and also fairly simple.

The true magic to the GFRC process actually happens with the forming technique. Forms can be made from a multitude of mediums. The flowing sink designs you see today are actually formed from a combination of traditional Melamine lumber, the use of fabric and even gum rubber sheeting is utilized to create these endless flowing designs. Once the form is built to accommodate the shape of the special requirement. First a very light low build type form oil or wax

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22 Concrete Contractor | December 2015 | www.forconstructionpros.com/concrete

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is utilized, if a thick oil is utilized the GFRC mix will pick up the build of the oil in the finished piece.

Once excess oil is removed from the form, the face coat is mixed. The face coat is generally applied to the form utilizing a Hopper gun powered by compressed air. The degree of initial set is monitored and at the optimal time the backer coat is mixed, fiber is then added into the final stage of the mix. At this point you’ll be working with the mix that closely resembles a cementitious fiberglass mix. The backer coat is then either sprayed onto the face coat utilizing a special spray gun or it is hand packed into position.

Once the backer mix is in place, it is consolidated utilizing a small handheld roller design for this task.

This process allows flawless pieces to be constructed in a very short time period compared to the traditional concrete casting process we all knew years ago. Any desired look or color

can be incorporated into this modern concrete construction technique.

ENDLESS DESIGN Once you understand and master the GFRC process you will find an unlimited creative outlet. Your work can bring on the look and detail of a super clean pinhole free fireplace surround or the rustic detail of freshly sawn wood. Design elements can be cast directly into the piece to bring on the realistic interpretation of a water warn fissure or void while not sacrificing strength.

Specialized minerals are also available to incorporate into the mix to bring a nice luminescence luster to the finished piece.

This can be a very unique and intriguing look you’ll see into the future with GFRC panels.

Problem: New or Existing Concrete Issues?

Ed. Note: Bart Sacco is President of Kingdom Products, www.www. kingdom-products.com.

With the introduction of GFRC mix designs, production time and application techniques have advanced considerably. Once you understand and master the GFRC process you will find an unlimited creative outlet and your work can bring on endless design possibilities.

Photo Credit: Troy Lemon

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www.forconstructionpros.com/concrete | December 2015 | Concrete Contractor 23

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SPOTLIGHT ON DECORATIVE CONCRETE

Finishing Techniques for CONCRETE COUNTERTOPS

As one of the few building materials created from raw ingredients, concrete is a fantastic material to design and work.

Developed by Buddy Rhodes, his signature look is called “Pressed”, and it involves manipulating a stiff, clay-like mix to leave voids and fissures that are then back filled with coordinating or contrasting colors of grout.

Photo Credit: Buddy Rhodes Concrete Products

D

By Jeffery Girard, P.E. ecorative concrete flooring techniques such as acid staining and stamping have been around for many years and provide beautiful looks often inspired by earth tones and nature. More exotic flooring finishes such as metallic epoxies, intricate stencils, and brightly colored dyes introduce even more possibilities.

Although integral pigments are sometimes used in decorative concrete flooring, most of these techniques use some kind of finish external to the base concrete.

Polished concrete floors do often involve manipulating the concrete itself, to expose aggregate and/or polish to a high sheen.

When we enter the realm of concrete countertops, sinks, fire pits and furniture (what I call “creative concrete”), we find that the majority of finishing techniques are integral to the concrete itself. Examples are exposed aggregate, polished, troweled, cream, salt and pepper, and pressed.

JM Lifestyles in New Jersey installs or ships their Woodform Concrete creations all over the world.

Photo Credit: JM Lifestyles

Just when we thought that decorative concrete had endless possibilities, we discover that creative concrete adds even more! This article explores and illustrates some of those finishing techniques.

PRESSED Perhaps the quintessential look for creative concrete is the one developed by a founder of the industry, the inimitable Buddy Rhodes. His signature look is called “Pressed”, and it involves manipulating a stiff, clay-like mix to leave voids and fissures that are then back filled with coordinating or contrasting colors of grout. The grout is a mix of cement, water and pigment with an acrylic polymer added to aid in bonding. Note that the mix design and the

casting technique are crucial to the success of this finishing technique.

With concrete countertops and other forms of creative concrete, often the forming techniques, mix design, casting technique and finishing technique are all inter-related, requiring a great deal of planning and thought in order to achieve a particular look.

CREAM This technique refers to precasting the concrete and then leaving the thin layer of cement paste that remains on the outer surface. I often call this “pop a perfect slab,” because the goal is to create a perfect mold with no defects in the casting surface. When you remove the concrete from the mold, it is also nearly perfect, requiring perhaps only a light honing with 400 grit wetdry sandpaper to remove any texture left by the melamine.

In practice, this can be Pictured here is a Cream finish, precast and vibrated concrete countertop.

Photo Credit: Jeff Girard, The Concrete Countertop Institute

24 Concrete Contractor | December 2015 | www.forconstructionpros.com/concrete

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REGISTER TO ATTEND THE ICPSC CONFERENCE

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SPOTLIGHT ON DECORATIVE CONCRETE challenging to achieve, because tiny pinholes may lurk just below the delicate surface. Using GFRC (glass fiber reinforced concrete) with a sprayed-in mist coat can help achieve a pinhole-free surface. Using a fluid, aggregate-based mix and vibrating is another way to achieve this.

Note that the mix design, mold making technique and casting technique are critical to the success of this finishing technique.

Closeup of sliced conch shell plus stone, recycled glass, and glow in the dark aggregate.

Photo Credit: Jeff Girard, The Concrete Countertop Institute

recipe as in the Pressed look).

This look captures the natural beauty and variation of concrete when the client desires a “solid” color. The risk is that if using an aggregate-based mix, too much cream could be taken off, exposing too much of the aggregate.

SALT AND PEPPER

EXPOSED AGGREGATE

My go-to look is what I call “Salt and Pepper.” To achieve this look, you hone off the thin layer of cement paste to expose the sand grains. Pinholes will be exposed as well, so you fill in with a color matched grout (using the same

Going beyond Cream, then beyond Salt and Pepper, we arrive at Exposed Aggregate. In this technique, decorative aggregates are mixed in the concrete, and the cured concrete is ground down to expose

the desired amount of aggregate.

The aggregates are often stone and glass, but can also be more exotic items such as shells or even glow in the dark aggregate! Typically decorative aggregate is mixed into a precast mix or it is sprinkled on or glued onto the mold before precasting.

EMBEDMENTS AND KNOCKOUTS A wide variety of decorative items can be embedded in concrete to achieve very unique and personal looks. I’ve embedded glass tiles of many sizes, vertically sliced wine glasses, plate glass on edge and backlighted, various copper shapes, metal gears, bicycle chains, race car engine parts, intricate stainless steel logos that were water jet cut, geodes, turquoise, fossils, and even cuff links.

Fiber optic cables could be considered a form of embedments too.

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26 Concrete Contractor | December 2015 | www.forconstructionpros.com/concrete

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The possibilities truly are endless with embedments. The only restriction is not to use materials that expand and contract, such as wood, or react with the concrete, such as uncoated aluminum (add a coat of lacquer.)

SPECIALTY

Tony Stewart and Bobby Labonte’s race car engine parts embedded in a retail counter.

Photo Credit: Jeff Girard, The Concrete Countertop Institute

I’ve pressed leaves into the cast surface, capturing every vein on the leaves. I’ve used foam knockouts to block out lettering and logos. I’ve used trim molding as a knockout to create a floral patterned edge.

It’s not possible to list every single look achievable with concrete.

Many creative concrete artisans have developed their own unique looks using intricate and skilled techniques they developed.

Dusty Baker of Stone-Crete Artistry in Tennessee has developed a technique using texture and glazing to create a look that surpasses natural stone.

JM Lifestyles in New Jersey installs or ships their amazing Woodform Concrete creations all over the world.

As you’ve seen, various finishing techniques such as honing, grinding, polishing, glazing and more are

used to create these looks, but mix designs, mold making techniques, and casting techniques are important as well.

Ed. Note: Jeffrey Girard, P.E., is the President of The Concrete Countertop Institute. For more information visit www.concretecountertopinstitute.com.

Dusty Baker of StoneCrete Artistry in Tennessee has developed a technique using texture and glazing to create a look that surpasses natural stone.

Photo Credit: Stone-Crete Artistry

UNLEASH VIBRANCE Aggretex® is the innovator in embedded aggregate material for concrete surfaces. Aggretex® offers a line of concrete additives that are cementitious slurry matrix compositions, to which decorative aggregates are added to provide beautiful, cost effective, easy-to-place decorative surfaces. Our experienced team of concrete specialists skillfully blend sophisticated combinations of chemical admixtures, fibers, supplementary cements, aggregates and vibrant pigments to support our customer’s design innovations. The possibilities are limitless—UNLEASH VIBRANCE.

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www.forconstructionpros.com/concrete | December 2015 | Concrete Contractor 27

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SPOTLIGHT ON DECORATIVE CONCRETE

The Science of

Color in Concrete

Concrete is a material that varies in many ways, so achieving a perfect color is as much an art as it is science.

By Shawn Hays and Ryan Moore

P

igment selection, the type of cement, aggregate size and color, water content, mixing technique and finishing methods all have a role to play in the overall final appearance of the decorative concrete surface.

CEMENT White cement provides a greater range of color possibilities and should be considered for bright and vibrant colors. White cement also yields greater reproducibility and consistency of color. For maximum brightness, particularly in the light pastel shades, white cement and the whitest aggregates should be used.

Grey cements can vary greatly between suppliers, from batch to batch, and green undertones can alter the final appearance of the desired color. Given the higher levels of iron and other impurities in grey cement, the color selection is limited to muted earthy tones.

AGGREGATES Typically there are two gradations of aggregates in a concrete product.

Coarse, consisting of gravel, crushed stone, pumice, expanded shale, slag or limestone. Fine, consisting of silica sand, rock dust or manufactured stone sand. Aggregate color and size will impact the appearance of decorative concrete. This impact is directly related to the degree of exposure of the final concrete surface. A heavily exposed coarse aggregate will detract for the concrete color and the human eye will typically see the aggregate color.

WATER Water not only makes a concrete mix workable, but also enters into chemical combination with the cement. The quantity of water used in a mix controls to a large degree the durability, strength and water tightness Photo Credit: Delta Performance Products of a concrete product. The higher the water content of the mix, the chemical reactions as the concrete lighter the color. Control of the water/ cures since pigment becomes incorcement ratio is vital for consistent porated into the concrete matrix. color from batch to batch.

Post cure, the pigments must survive long term UV exposure.

INTRODUCTION TO PIGMENT

INORGANIC PIGMENTS

Pigments are insoluble particles that absorb certain wavelengths of light while reflecting other wavelengths allowing colors to be observed. The shape and size of pigment particles plays an important role in light reflection.

Pigment particles can be spherical, rod shaped, plate-like, or irregular depending on individual chemistries.

The shape can alter the rheology of the material and can have an impact on the water demand in some cases.

It is important to test a pigment in a smaller sample in order to make necessary adjustments.

Hydrated cement, by its nature, is a harsh chemical environment for most materials, and for pigments specifically. Care must be taken to choose pigments that can survive the

The industry standard for integral color in concrete, ASTM C979, spells out requirements and test procedure for pigments used in concrete and specifies inorganic pigments as the preferred pigment of choice. Inorganic pigments are chemically stable, and typically won’t have adverse effects on the concrete as long as used within recommended ranges, typically less than 10 percent of the cement content by weight. Synthetic iron oxide pigments are inexpensive and there is a wide enough variety to achieve many desired earth tone colors. Naturally occurring ochres and umbers contain iron oxide along with other minerals and also produce unique shades of assorted earth tones. Chromium oxide provides a stable green

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pigment. Titanium dioxide is useful for achieving light colors, whites, as well as making light grey when used in grey cement. Cobalt oxides allow for various blues and teals but can also be more expensive than other oxide based pigments.

been developed since the implementation of ASTM C979. There are now bright yellows, reds, and violets on the market that can expand the possibilities of concrete color.

ORGANIC PIGMENTS

Formulating a color can be as straightforward as making samples of a single pigment at different loading rates until the desired shade is matched or it can be complex blend of pigments in order to achieve a very specific look. Generating a custom color palette can be a process of mixing primary colors together to create a handful of unique colors.

Matching a specific color precisely can be a quite complex, often involving multiple attempts to dial in the exact shade required.

One of the key areas of focus at Delta Performance Products is to provide custom color matching and blending,. A physical sample or paint

Breaking the color barrier for concrete is achieved by using organic pigments in combination with inorganic pigments. Organic pigments are brighter, much stronger, and cleaner than the oxides and thus can help achieve deeper colors than with oxides alone. Organic pigments can affect water demand and cure time, among other side effects. Carbon black is one of the most common organic pigments used in concrete, and there are limits to its use. Copper phthalocyanine pigments offer various shades of blue and green. The use of these pigments requires some expertise and many new chemistries have

FORMULATING COLOR AND COLOR MATCHING

name or number is often all that’s required to get an accurate color match. Technology is a helpful aid in the color matching process, primarily relying on the spectrophotometer.

This piece of equipment reflects light off a sample and translates the data into a three dimensional graph allowing a more objective analysis of color.

This graph allows easy comparison between a sample to match and the sample being tested allowing precise adjustments to be made to the formula. Verifying colors under a light booth with different light sources is also a key step in the color process due to the phenomenon of metamerism in which colors vary based on lighting conditions.

CONCLUSION Understanding the available technology will be an important part of maintaining customer satisfaction as color becomes a more important aspect of the concrete industry.

www.forconstructionpros.com/concrete | December 2015 | Concrete Contractor 29

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SPOTLIGHT ON DECORATIVE CONCRETE

By Jeremy French

Finding Success in

Artisan Concrete What are the tools needed for a contractor to find success in artisan concrete work?

“Are those countertops granite?”

“No, they are concrete.”

“Really? How much do they cost?”

“Starts at about $100 per square foot.”

“WHAT!!??”

T

his is a not an uncommon dialogue when delivering concrete countertops to a jobsite. The concrete contractor on site hears these countertops are made out of the same material they work with everyday, but the price these countertops command is 10 or 20 times higher than the work they are doing. A few hours on the Internet, a quick trip to the sign shop, and the truck for the concrete contractor shows off their newest offering — “Driveways, Stamped Concrete, and CONCRETE COUNTERTOPS!” A few months later, that promotional magnet affixed to the contractor’s truck has found its way to the dumpster. After seeing this scenario play itself out over and over, it begs the question— What keeps that magnet out of the dumpster? What does it take to make a successful business creating artisan concrete?

Concrete is a paradox at every turn. It is the most widely consumed material on the planet next to water; yet ask any person on the street “What is concrete?” and you are likely to get an impressively wide range of wrong or incomplete answers.

Concrete is responsible for the infrastructure that holds up modern

civilization, considered ‘indestructible’, yet concrete is brittle and it cracks.

Buddy Rhodes Concrete Products Concrete is used in the largest buildings and public works projects in the world, yet it is also used CLIENT RELATIONSHIPS to make incredibly delicate and This is the beginning of success beautiful jewelry. and failure. This is true of any busiThis paradox shows itself when ness, and most principles for client we ask what is the common thread relationships hold true in artisan conamong people who build things out crete as they do in any other trade. of concrete. Concrete is the comWhere it gets difficult is when you are mon thread, right? Let’s examine setting expectations for a material that thought. that doesn’t have generations of use Regardless of the application, to reference. Everyone knows what to working with concrete is like a dance. expect from a wood top, they have Successful concrete contractors a wood table that was passed onto are like good choreographers— them from their grandparents. The they arrange all of the players and same can’t be said for concrete, so the the parts so that everything goes role of the contractor is to begin the smoothly. It is a matter of having good education process. If expectations are client relationships with measured out of whack, this project can come expectations, the right tools, an orgaback to bite you well down the road. nized environment, a qualified staff, the appropriate formwork, the right THE RIGHT TOOLS mix design, a quality set of partners The artisan concrete shop looks in all of the associated trades, and the far more like a cabinet or furniture list goes on. The successful contracbuilders shop than anything else. The tor knows that in order for the project tools are designed for fine details and to go off without trouble, if any of the finishing rather than the more industriplayers and parts aren’t in place, then ous tool kit of your typical GC. the potential for disaster is high.

The ability to arrange the dance ORGANIZED ENVIRONMENT before concrete ever enters the picMuch of the work of artisan conture is the common thread among all crete will happen in a shop enviof those who work with concrete. It ronment, but that changes during is then no wonder that the successful the installation of the projects when driveway contractor who has dediwarranted. Having the ability to trancated his life to work with concrete is sition between these two environunable to make sense of countertops, ments takes a certain flexibility, preequally true for the countertop artiparedness, and discipline. The order san trying to pour a driveway. of the environment will be reflected So the real question is, what are the in the finished project, whether you elements that need to be managed? want it to or not.

32 Concrete Contractor | December 2015 | www.forconstructionpros.com/concrete

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This picture illustrates just how different artisan concrete can look from a slab.

Pictured here is Molly Rose Freeman, an artist who created the rendering that eventually became the piece of concrete she is holding.

Photo Credit: Buddy Rhodes Concrete Products

QUALIFIED STAFF Having someone that works from the time they punch in until the moment they punch out is an asset in any company. Then there is the person that puts their head down and really forges through the day with a vigor expressed by few—this person is a rarity and worth gold on many jobsites. That person is often a liability in an artisan production. The best staff are people with an eye for detail, someone who is diligent, thoughtful, and focused, and who is also not afraid to get dirty.

In artisan concrete it is all about the details, and the details often fall in the hands of the staff.

suppliers range from raw material providers that offer high-quality ingredients and tools for concrete specific tasks, to material suppliers that provide sheet goods to the cabinet trade.

Metal and wood fabricators come in real handy for collaborative purposes to round out the offerings from the artisan to the public.

If you’re a contractor venturing into

artisan concrete, these are areas that should be considered before the trip to the sign shop, and then perhaps the “Concrete Countertops” magnet won’t end up in the dumpster.

Ed. Note: Jeremy French represents Buddy Rhodes Concrete Products. He can be reached at Jeremy@buddyrhodes.com; www. buddyrhodes.com

APPROPRIATE FORMWORK When casting an object that will be viewed from two feet away every night and day, an object that is at the center of someone’s home physically and functionally, there is not a lot of room for error. The size of the tolerance is what can’t be read on the tape measure, and the formwork and preparation must reflect this expectation.

MIX DESIGN This is an area where the ‘concrete’ of artisan concrete, and the ‘concrete’ of most other trades are the same in name only. Artisan concrete mix designs begin with a very stringent set of demands. It must be incredibly dense, yet lightweight, and have a high tensile capacity with high early strength. This is the tip of the iceberg, and a whole volume could be written on the subject. Suffice to say, some consideration in this realm is critically important.

PARTNERS There is a wide range of suppliers and subcontractors that are of extreme value to the artisan. The

www.forconstructionpros.com/concrete | December 2015 | Concrete Contractor 33

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CONCRETE REPAIR

By Jay H. Paul, S.E., FACI

Rethinking Concrete Repair A new guide helps concrete professionals interpret performance-based code requirements.

A

new concrete repair code is changing the way concrete contractors and specifiers approach their work. The American Concrete Institute’s (ACI) Code Requirements for Evaluation, Repair, and Rehabilitation of Concrete Buildings (ACI 562-13)—the first code specifically for repairing reinforced concrete—provides clearly defined, uniform requirements aimed at extending the service life of existing structures.

Because repairing existing structures involves many variables and unique considerations, the code is designed to give concrete professionals significant latitude in determining the best approach to any given project, considering factors such as a structure’s age, environmental conditions, and original materials used. In fact, ACI 562 is the first code by ACI to incorporate both performance and prescriptive requirements, allowing licensed design professionals to use their judgement while following a minimum baseline of requirements.

Now, the American Concrete Institute and the International Concrete Repair Institute (ICRI) have published the Guide to the Code for Evaluation, Repair, and Rehabilitation of Concrete Buildings, a resource that makes the code easier to understand and implement. The companion guide helps designers and contractors interpret the requirements of ACI 562 and apply them to specific situations.

NAVIGATING A NEW KIND OF CODE Carl J. “Chuck” Larosche, principal at Wiss, Janney, Elstner Associates (WJE) in Austin, Texas,

says his architecture and engineering firm is often asked to evaluate the capacity of existing structures, so they can be used in new ways.

Larosche follows ACI 562 requirements to determine equivalent strengths for concrete and reinforcement, as he did recently for the Port of Houston Authority.

The port authority wanted to know if several of the older concrete wharves could be strengthened to handle increased capacity. “The original material properties were not cited in the record set of construction documents,” says Larosche, “so we used ACI 562 to conduct a material evaluation and determine equivalent strengths.” As a result, WJE was able to confirm the existing structural capacities and recommend appropriate design modifications accordingly.

Larosche advises concrete professionals to refer to the code’s chapter on “Evaluation and Analysis” for guidance with structural evaluations—a starting point for assessing existing structures. The Guide to

The Guide to the Code Requirements for Evaluation, Repair, and Rehabilitation of Concrete Buildings provides user-friendly flowcharts that illustrate key decisions that must be made, such as determining material properties during structural evaluation. the Code for Evaluation, Repair, and Rehabilitation of Concrete Buildings walks users through each chapter of ACI 562 with insights into how each section of the code applies to different aspects of concrete repair.

Flowcharts illustrate critical points in the process, such as determining material properties. The guide also uses sidebars to highlight related topics and references that are not explicitly covered by the code, such as, “Is a Structural Evaluation Always Required?” This straightforward approach clarifies the benefits of ACI 562 for all project stakeholders: designers, contractors, building owners, and building officials.

Contractors may find the

34 Concrete Contractor | December 2015 | www.forconstructionpros.com/concrete

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MK Diamond Products manufactures a full line of professional concrete saws that include gas, diesel, electric or propane models with blade capacity from 14” to 42”.

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Honda, Kohler or Subaru Engine or Leeson Motor Depth of Cut: 5-1/2” FEaturES: • Compact, lightweight, engineered for maneuverability and reliability • Can be used for wet or dry cutting • Corrosion resistant cast-aluminum blade guard • Built-in water distribution system supplies water to both sides of blade

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CONCRETE REPAIR ESTABLISHING REPAIR STANDARDS ACI 562 was published in 2013, by a committee formed to carry out goals stated in the Vision 2020 plan for the concrete repair, protection, and strengthening industry. One goal of the plan, established by the Strategic Development Council (a council of the ACI Foundation), was to create a repair and rehabilitation code that would improve the efficiency, safety, and quality of concrete repair.

By establishing minimum requirements for evaluation, design, materials, and construction practices, ACI 562 raises the level of repair and durability performance. The code also establishes clear responsibilities between owners, designers and contractors, and provides building officials with a means to evaluate rehabilitation design. In the past, inspectors have defaulted to codes for new construction, which could result in unnecessarily costly repairs.

ACI Committee 562, Evaluation, Repair and Rehabilitation of Concrete Buildings, spent seven years developing the code with the ultimate goal of preserving more existing concrete structures by unifying industry practices.

guide’s explanation of specific roles and responsibilities most beneficial. Chapter 9 (Construction), summarizes the code’s requirements for three considerations often encountered in repair projects: stability and temporary shoring, temporary conditions, and environmental issues.

ACI 562 requires licensed design professionals to (LDPs) include temporary shoring and bracing requirements in the repair documents. Typically contractors will hire a third party LDP to design the shoring and bracing, who must then the provisions within ACI 562.

Contractors are responsible for determining the methods and means of executing the actual repair process, per the repair contract. The guide clarifies the importance of collaboration

and communication between designers and contractors.

Once repairs are underway, the contractor should notify the designer if any deterioration, faulty construction, or damage observed during construction is more severe than anticipated.

The designer can then determine what measures are necessary to maintain structural integrity while repairs are implemented.

A sidebar in this chapter provides an example of a highrise repair project in which several columns collapsed as unsound concrete was being removed. The example points to ACI 562 provisions that would guide the process of securing and evaluating the structure, and each party’s responsibilities.

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FROM DESIGN STANDARD TO JOBSITE The Guide to the Code for Evaluation, Repair, and Rehabilitation of Concrete Buildings further illustrates how ACI 562 requirements apply to common repair scenarios through detailed project examples, including: • Typical parking garage repairs • Typical facade repairs • Repair of historic structure for adaptive reuse • Strengthening of two-way flat slab • Strengthening of double-tee stems for shear Alongside each project description are references to ACI 562 requirements for each phase, such as identifying the design basis code, evaluating concrete and reinforcement strength, and determining load factors and load combinations.

One example describes a situation

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A new reference guide helps concrete designers and contractors apply provisions of concrete repair code ACI 562 using real project examples, such as this precast/pre-stressed double-tee roof at a water treatment plant.

Photo Credit: American Concrete Institute

in which cracks were discovered in the concrete roof beams at a water treatment plant. The guide includes photos and drawings of cracks at the ends of precast/pre-stressed double-tee stems, as well as repair or replacement options that were considered in accordance with ACI 562.

In this case, the owner opted to install bonded carbon fiber reinforced polymer (CFRP) strips at the

double-tee stem ends, based on cost and limited interruption to operations. The guide references ACI 562 provisions for the repair design, as well as the contractor’s responsibility for environmental considerations such as controlling dust and removing debris — especially in the presence of potable water.

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CONCRETE REPAIR have standards for routine repair methods that weren’t covered before,” says Larosche. For example, he says, previous codes did not include a standard definition for bond strength or requirements for quality conformance testing related to installing CFRP.

USING A COMMON ‘PLAYBOOK’ By reviewing the project examples in the Guide to the Code for Evaluation, Repair, and Rehabilitation of Concrete Buildings, designers and contractors will become familiar with the code’s new provisions and how they relate to the repair strategies they execute every day. This is a valuable exercise, as ACI 562 is increasingly becoming standard practice.

The code can be adopted directly by local jurisdictions and municipalities, and may also become part of the International Existing Building

The contractor elected to install CFRP sheets, rather than strips, to reinforce precast/prestressed double-tees at a water treatment plant.

The sheets were finished with an acrylic coating to enhance the aesthetics of the beam end repairs.

Photo Credit: American Concrete Institute

Code (IEBC) in 2018.

“When designers, contractors, building officials and inspectors are working from the same code we all have the same expectations,” says Larosche. “It puts everybody on a level playing field.”

The Guide to the Code Requirements for Evaluation, Repair, and Rehabilitation of Concrete Buildings is now available in print and digital formats at www.icri.org and www.concrete.org.

Ed. Note: Jay H. Paul, S.E., FACI is a Senior Principal of Klein and Hoffman, Inc. in Chicago, Illinois and a member of the International Concrete Repair Institute and ACI Committee 562 – Evaluation, Repair, and Rehabilitation of Concrete Buildings.

38 Concrete Contractor | December 2015 | www.forconstructionpros.com/concrete

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New c tri c e l E tors o M

Optimum concrete consolidation Wacker Neuson’s flex-shaft vibrator system offers a variety of motor, head and shaft combinations to choose from for cost effective concrete consolidation. The new 1.5-hp and 2.5-hp motors are lightweight, extremely durable and the quick disconnect makes flex shaft exchange easy. With a solid reputation for reliable products and service, Wacker Neuson is the brand to you can trust and your partner for the long run.

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PRODUCT FOCUS

CONCRETE ATTACHMENTS

E-Z Drill 210 Series Concrete Drill Attachments

Minnich Machine-Mounted Dowel Pin Drills

This pneumatic concrete drill attachment series includes the three-gang Model 210-3 EQ MT, four-gang Model 210-4 EQ MT and five-gang Model 210-5 EQ MT. • Compatible with most models of backhoes and excavators • Capable of drilling 5/8- to 2 -1/2-in.-diameter holes at a depth of 18 in.

• Each drill motor requires a minimum of 100 cfm for operation • Minimum of 300 cfm required to power the Model 210-3 EQ MT ForConstructionPros.com/10278334 World of Concrete 2016 Booth #C4439

This series of self-contained dowel pin drills includes excavator-, backhoe- and skid-steer-mounted models suited for horizontal patchwork jobs with a relatively long distance between the areas to be drilled.

• Available in hydraulic and pneumatic options capable of 18-in. maximum drill depths • Two-, three-, four-, fiveand six-drill units with operating weights from 1,250 to 2,125 lbs.

• Powered by a compressor mounted to the counterweight of the carrier or in the bucket of a backhoe • Side shift standard on A-2 and A-3 and optional on the A-4 through H-6 models • Feature 330-degree drill bed rotation, adjustable drill height, depth and centers and available dust collection ForConstructionPros.com/11104146 World of Concrete 2016 Booth # C5184

MB America MB-L 160 Bucket Crusher Designed for a skid steer or backhoe, the MB-L 160 model offers a production rate up to 25 tons per hour.

• Jaw crusher • Separate concrete from rebar • Adjustable output from 2 to 0.5 in. minus • Crush material from concrete to granite • Weight: 3,000-lbs.

• Goes onto a 3.8 ton excavator • Low maintenance ForConstructionPros.com/10879162 World of Concrete 2016 Booth #O30522

Danuser CB40 Hammer Concrete Breaker The CB40 concrete breaker delivers up to 82,000 lbs. of impact force with each cycle.

• Breaks up to 9-in.-thick reinforced concrete • Operates on any skid steer with 12 to 30 gpm without additional setup • Anti-dry fire feature prevents unnecessary firing and improves durability of the machine ForConstructionPros. com/11126701

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Paladin Attachments’ FFC Concrete Claw offers more productive operation with its lower profile and low mounting height that allows material transfer while utilizing boom/ loader arm supports.

• Easily replaceable teeth with 1.5-in.-wide shanks decrease downtime • Shanks and end plates made with high-strength T-1 steel and a 1-in. by 8-in. wear-resistant pacal steel tapered cutting edge • Working width of 24 in.

• Rated capacity on machines that have an up to 32,000-pound operating weight and/or 10,000-pound lift capacity ForConstructionPros.com/11501349 World of Concrete 2016 Booth #C4319

40 Concrete Contractor | December 2015 | www.forconstructionpros.com/concrete

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#1 SUPPLIER OF BOOM EXTENSION CONCRETE SCREEDS THE WORLD’S

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ScreedSaver MAX with Ligchine/Topcon 3D GPS satellite control system placing a multi-contoured parking lot. This versatile control system easily transfers between any ScreedSaver machine, as well as your entire fleet of Excavators, Dozers, Graders, and Curb machines.

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› Optional roller heads for pervious and topping slabs

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PRODUCT FOCUS

CONCRETE ATTACHMENTS Bobcat Hydraulic Breakers Couple Quieter Operation with Increased BPM These hydraulic breaker attachments feature Auto Power, which automatically regulates pressure throughout operation and limits excessive pressure at startup.

• Energy chamber keeps the nitrogen pressure constant with no periodic charging required • ylindrical breaker cradle design improves access to jobs in confined areas • Steel ring system retains the tool bushing and protects grease access, plus provides for quick tool changes • Upper and lower shock absorbers isolate the breaker from the housing for reduced noise and vibration • Bob-Tach and X-Change attachment mounting systems ForConstructionPros.com/12109656 World of Concrete 2016 Booth #C5479

Cat H35E, H45E, H55E and H65E Hydraulic Hammers The H35, H45, H55 and H65 flat-top hydraulic hammers are designed for use with compact excavators, skid-steer loaders and backhoeloaders.

• Available in enclosed, silenced, cases or sideplate versions • Engineered to match auxiliary flows and pressures of Cat machines, plus allow installation on competitive equipment • Automatic shut-off ForConstructionPros.com/11239471 World of Concrete 2016 Booth #C6061

Brokk Planer Attachments Brokk offers four planer models for use with its remotecontrolled demolition machines. The BCP 250 and BCP 350 utilize skis that are set against the surface and the grinder runs along a track to remove a 1/4- to 2-in. layer of concrete. The PLB 200 and PLB 300 models do not run on tracks, enabling operators to freely grind in wide, sweeping motions to cover large swaths.

• The attachments grind at rates up to 80 sq. ft. per hour at up to 20 ft. above the ground • Operators can ratchet down the two-drum grinder in 1/16-in. increments to create a uniform, binding surface. Steel shrouds encase the two-drum grinders to catch flying concrete shrapnel and reduce dust particles.

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EDCO introduces Magna-Trap Systems, opening a new era in concrete grinding surface preparation equipment and tooling specifically designed for the rental industry. With both rental and retail opportunities, EDCO’s Magna-Trap System solves virtually every concrete grinder surface preparation application.

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The EZ Screed Tool is designed to be used in an upright position in place of the traditional “bent over method”. It is faster and more effective in the leveling of concrete, resulting in a more precise professional finish to your concrete job and saving thousands of dollars in labor costs yearly. EZ Screed Tool is designed for walks, driveways and slabs of various sizes.

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42 Concrete Contractor | December 2015 | www.forconstructionpros.com/concrete

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Concrete Mixer Attachment for Skid Steer Loaders from Western Material & Design, LLC

Trimble 3D Grade Control System for Bobcat Grader Attachments The GCS900 3D grade control solution is now available for Bobcat all-wheel steer, compact track and skid-steer loaders, allowing small contractors to work faster and more effectively on complex projects that require digital designs and 3D machine control.

• System uses digital 3D models prepared in Trimble’s Business Center – HCE office software • Suited for footpaths, parking lots and sidewalks • Available as an upgrade from the 2D laserguided and sonic/slope systems already offered by Bobcat ForConstructionPros.com/12114304 World of Concrete 2016 Booth #N1037

The FasTrac Concrete Mixer converts any skid steer loader into a portable concrete mixer. Portability and versatility make the FasTrac ideal for a broad array of applications where speed is important, and space may be limited. The model 750 has a three-quarter cubic yard capacity, while the model 500 has a half cubic yard capacity.

• Use wherever fast-setting concrete is used • Contractors can pour on the left or right side, and the discharge chute extends up to six feet, providing more latitude when positioning the mixer • The pour gate seals to prevent water and material from escaping, and makes the unit ideal for selfleveling applications that involve a more fluid mix • Weighing 750 lbs.

• Powered by a hydraulic motor connected to standard quick-disconnects for skid steer loaders ForConstructionPros.com/12134275

BackSaver Hammer Drill Attachment Save your back and get the job done. The patented concrete hammer drill attachment may change the way you use your hammer drill forever. With the BackSaver contractors will be able to: • Stand and work to help prevent back injury • Drill concrete dowel bars more easily • Apply more pressure and use less energy • Increased productivity when drilling concrete • BackSaver attaches to a variety of DeWalt drill models.

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CONCRETE COATING TOOLS

Seeking Manufacturers Reps and Distributors across the U.S.

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PRODUCTS

World of Concrete

PREVIEW

A compilation of products from scheduled exhibiting companies.

Polish Off Your Concrete Flooring Projects with INDUROSHINE by W. R. MEADOWS INDUROSHINE, a polished concrete flooring system by W. R. MEADOWS, is an environmentally friendly and long-lasting choice for your polished concrete flooring needs. The INDUROSHINE system, when combined with W. R. MEADOWS’ LIQUI-HARD, a concrete densifier and chemical hardener, creates an architectural and aesthetically pleasing floor that requires neither expensive coverings/coatings nor frequent maintenance.

ForConstructionPros.com/12127932 World of Concrete 2016 Booth #S10407, O31557

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Removal, Prep, Polish, Maintain EZ Screed Tool

CALL TODAY! 800-622-2048

3 Service/Showroom Locations 8 Sales Locations www.niagaramachine.com info@niagaramachine.com

The EZ Screed Tool is used in an upright position for faster, more effective leveling of concrete and a more precise finish to the concrete job.

• Lightweight handle • 3-, 4-, 5- and 7-ft. aluminum screeds available ForConstructionPros.com/10080016 World of Concrete 2016 Booth #N3049

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Hook Bolt Driver Ties Two Pavement Joints Together The hook bolt driver is a tool used to fasten epoxy coated hook bolts into couplers. Hook bolts are used in longitudinal joints in concrete pavement to tie two pavement joints together.

• The driver can be attached to any cordless drill • Easily holds the hook bolt when snapped into the hook bolt driver • The hook bolt driver is 75% more efficient fastening hook bolts then hand tightening ForConstructionPros.com/12104592 World of Concrete 2016 Booth #N3115

The Refresher from Aztec Products

Atlas Copco’s TEX 830 Rivet Buster

The Refresher, a propane polisher, stripper, buffer and sander features all steel construction and planetary drive to eliminate shadowing and side torque.

It also includes three sets of quick changes heads for stripping, polishing and burnishing concrete.

• Standard dust control functionality • Standard 8 gallon water tank • 330 lbs. head pressure • Compatible for use with 4” ceramic or resin diamond pucks and diamond impregnated pads • Low profile – fits under 8” shelf ForConstructionPros.com/12135219 World of Concrete 2016 Booth #O32126

The Atlas Copco TEX 830 rivet buster gives contractors a lightweight and easy-to-use tool for demolishing concrete, metal and steel on construction and renovation jobs. The rivet buster weighs just 30 pounds and generates as many as 1,140 bpm for consistent, hard-hitting power.

• 6-ft. whip hose with a claw coupling to minimize setup times • Push and twist the coupling to quickly attach the hose to an air compressor • The unit requires 44 cfm to operate • Available with a pistol or D-style handle for optimal comfort at a variety of angles • Can be used with 6-, 8- and 11-inch moil points and narrow chisels ForConstructionPros.com/12135820 World of Concrete 2016 Booth #C4641

Specialty Winches and Capstans for the Concrete Industry

Padco T-Bar Applicators Padco T-Bar Applicators apply a smooth, uniform coat of finish to concrete, vinyl, tile and terrazzo surfaces. Choose among Nylfoam, NanoFlock, Woven or Synthetic Lambswool.

Then apply a smooth bubble and lint free finish, at a rate of up to 20,000 sq. ft. per hour.

• Great for use with both oil modified and waterborne finishes • Available in a wide variety of sizes ForConstructionPros.com/12135882 World of Concrete 2016 Booth #S12057

The Euclid Chemical Company

QUALITY CONCRETE PRODUCTS

WINCH

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Designed for Outstanding Performance and Safety BLOOM Mfg. Inc. www.bloommfg.com

Independence, Iowa 50644 FAX 319-827-1140 PHONE 319-827-1139 800-394-1139

“Custom Engineered Solutions Since 1910”

INCRETE SYSTEMS quality decorative concrete products and innovative engineered systems.

• STAMPED CONCRETE PRODUCTS

• STAINS & DYES

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• STAMPED & TEXTURED OVERLAYS

• ARCHITECTURAL WALL SYSTEMS

1611 Gunn Highway • Odessa, FL 33556 800-752-4626 • www.increte.com

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ICPSC Returns to

World of Concrete Make plans to attend the International Concrete Polishing and Staining Conference in conjunction with World of Concrete.

By Ryan Olson

A

few months ago the International Concrete Polishing and Staining Conference (ICPSC) formed a long term partnership with AC Business Media (ACBM), publisher of Concrete Contractor magazine. This partnership will serve to re-launch and grow the ICPSC to make it the premier concrete polishing event.

On February 1, 2016 the International Concrete Polishing and Staining Conference (ICPSC) returns to Las Vegas at the World of Concrete 2016. This exclusive, oneday conference will offer polished concrete contractors the opportunity to learn from industry experts, sharpen your business skills and network with other contractors who polish concrete floors.

The ICPSC conference began in 2008 when founders and concrete polishers, Charlie and Jason Griffasi of Concrete Innovation Inc., (Buffalo, N.Y.) realized the only polished concrete education available was from the manufacturer where your equipment was purchased.

“Realizing that the main goal of the manufacturer is to promote what they sell we wanted to set a

venue that would offer unbiased information,” Charlie Griffasi says.

“All of the seminars are presented by industry experts and experienced contractors. Every presenter is directed to be topic specific and no product or equipment promotion is allowed.”

According to Griffasi, the mission of the ICPSC is to be a “Big Tent” within the polished concrete industry.

“This gives us the opportunity to present all points of view without a bias. We want to present advancements in the industry and let those in the field decide for themselves what they choose.”

WHY CONTRACTORS SHOULD ATTEND ICPSC Traditionally, the ICPSC is an international event. It brings together contractors and manufacturers from all over the world. It allows an unequaled opportunity to network with other contractors and there is no hesitation to share knowledge.

Contractors who attend the ICPSC at the World of Concrete will have the opportunity to catch-up with what the industry is doing presently as well as learn about new trends in the industry. Attendees will know what works and what doesn’t

2016 and will walk away with a feeling of community that an industry needs to grow and prosper.

“The industry is always advancing,” Griffasi says. “This is the only place where a contractor one can get all the information in an unbiased format and decide for themselves what path they want to take to grow their business.”

The ICPSC brings together a segment of the industry to discuss trends and techniques, allowing the industry to grow in a united direction.

“By allowing the industry to read from the ‘same Playbook’ it helps to insure its sustainability, growth and direction,” Griffasi says.

Whether you’re new to the industry or an experienced concrete polisher, the ICPSC is THE place to learn about the latest and greatest in the concrete polishing world.

Ed. Note: Register now for the International Concrete Polishing & Staining Conference (ICPSC) in Las Vegas, February 1, 2016. Visit www.ICPSC365.com for more information or e-mail Ryan Olson, Conference Manager at rolson@ ACBusinessMedia.com.

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(800) 331-1423 (215) 393-4800 FAX www.aztecproducts.com

THE REFRESHER

Propane 4-in-1 Honing and Polishing Machine ✔ Hone and Polish Concrete ✔ Burnish Concrete ✔ Strip VCT ✔ Sand Wood Floors Includes 3 sets of 3 quick change drivers/brushes

Hands On Demo at World of Concrete Las Vegas Feb 1-5, 2016 Outdoor Silver Lot: O-32126

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FOUNDATION Q&A

By James R. Baty II

Acceptable Tolerances for Residential Basement Slabs

The Concrete Foundations Association explains the conditions for evaluation of floor thickness tolerances vs. minimum required thickness in residential basement slabs.

Q

uestion: We have a project nearing completion where we prepped for a 3.5-inch thick floor slab. We ordered and placed enough concrete to justify the measurements and now the homeowner is debating the thickness of his basement slab. The owner cored a hole in the bathroom area and that spot measured only 2.75-inch thick. Is there a commentary or a standard on this? We believe the thickness is very challenging to control perfectly when the sub-grade consists of pea-fill.

– Contractor (Indiana)

A

NSWER This issue is a common application of the conflict between minimum performance requirements and recognized construction tolerance.

It is both natural and practical to identify the necessity of tolerance during construction as long as life safety, performance quality or durability is not put at risk. This is why code minimums have been created. Tolerances, however, are not identified by the general building code, in this case the International Residential Code (IRC) as they are often established by reference to approved documents. In the case of concrete construction, ACI 117 Standard for Tolerances is the primary referenced document.

In that document for cast-in-place

slabs on ground there are three applicable tolerances: 4.4.1 Top surface of slabs Slabson-ground........................ 3/4 in.

4.4.5 Fine grade of soil immediately below slabs-on-ground .................................... 3/4 in.

In these two tolerances, the recognition of the challenges faced between top surface and bottom surface control is placed. The top surface is a measure of finishing technique and placement accuracy while the bottom surface is a measure of the subgrade condition and the variability of aggregate compaction and size or soil excavation. This second tolerance, as noted in the commentary for this section, is specifically established for the sake of facilitating installations of slabs that can comply with the thickness requirements of a code yet taking into consideration the impact of the prepared subgrade. The final tolerance from ACI 117 provides: 4.5.4 Thickness of slabs-onground Average of all samples .................................... –3/8 in.

Individual sample......... –3/4 in.

Here the thickness of the slab is directly addressed. Two points are raised with these tolerances.

The first is that any one section of a slab may have a tolerance applied to it. In the event that a single area falls out of tolerance, or if there is concern for a considerable amount of the slab to be affected, the sampling

of the slab may proceed in order to ensure that the overall element doesn’t fall outside of an average.

This is intended to provide for the performance of the slab over the entire area. Correspondingly, this tolerance section continues to provide in commentary, information to direct the sampling of a slab concerned to be out of tolerance in its thickness.

Perhaps the most applicable to a residential basement application would be the following provision: 4.5.4.1 Minimum number of slab thickness samples, when taken, shall be four (4) for each 5,000 ft.2 or part thereof.

In other words, if there is enough of a concern to warrant the sampling of the thickness through the taking of cores, only four are necessary within a large size home. The average of these four thickness should not vary by more than 3/8 inch from the specified minimum thickness, which the IRC provides as 3.5 inches.

Absolute minimum thickness for a concrete slab as provided by the IRC is only a portion of the information to consider. This requirement coincides with the minimum concrete strength requirement found in Table R402.2 of 2,500 psi. As a minimum requirements standard, the IRC does not provision for increased strength or other design decisions in its prescriptive criteria. Instead, IRC R104.11 establishes that the minimum provisions of the code can be waived based on the review

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and interpretations of provided information supporting an alternative position.

Slab Thickness Tolerance (ASCC Position Statement #9) published by the American Society of Concrete Contractors further defines the necessity of acceptable tolerances for concrete slab construction. It recognizes that such variations in slab thickness are generally not issues of strength deficiency. While the paper sets forth information about the acceptable averages for deviations, perhaps the most supportive statement is that for increases in concrete strength compensating for decreases in slab thickness. This can also be applied to average deviations in slab thickness. Likewise, the subgrade k-value or the compaction level may also be increased to allow for standard deviations in slab thickness.

Achieving the intended performance of concrete slabs is important.

Understanding the points of control and alteration in approach to adapt to changes in site conditions and other factors is important to provide quality assurance. These also make the conversation much easier to move toward positive and constructive resolutions when challenges in the field arise.

Farmington Hills, MI 48331 | Phone: 248-848-3700 | www.concrete.org 3. Slab Thickness Tolerances, ASCC Position Statement #9 published by the American Society of Concrete Contractors, 2025 S. Brentwood Blvd., Suite 105, St. Louis, MO 63144 | 866-788-2722 | www. ascconline.org

Jim Baty is the Executive Director for the Concrete Foundations Association after having served as Technical Director since 2001.

Ed. Note: Want to know more?

Contact CFA Executive Director, Jim Baty at 866-232-9255 or by email at jbaty@cfawalls.org. The CFA is a national association with the mission to support the cast-in-place contractor as the voice and recognized authority for the residential concrete industry.

References: 1. 2015 International Residential Code For One- and Two-Family Dwellings published by the International Code Council, Inc., 4051 West Flossmoor Road, Country Club Hills, IL 60478-5795 | Phone: 888-4227233 | www.iccsafe.org 2. Specification for Tolerances for Concrete Construction and Materials (ACI 117-10) and Commentary published by the American Concrete Institute, 38800 Country Club Drive,

See what we have in store for 2016.

From flat saws and power cutters to core drills and demolition robots, we have a lot to offer! See the latest at World of Concrete 2016. Visit us at outdoor booth #O30166. To learn more, visit www.husqvarnacp.com

17400 West 119th Street • Olathe, KS 66061 • T 800-288-5040 • F 800-825-0028 Copyright © 2015 Husqvarna AB (publ.). All rights reserved. Husqvarna is a registered trademark of Husqvarna AB (publ.).

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By Ryan Olson

KEY PLAYERS Owner: Steiner and Associates General Contractor: Hoar Construction Concrete Contractor: Lithko Concrete, Cincinnati, Ohio Polished Concrete Contractor: Jeffco Concrete, Tuscaloosa, Alabama

Polished Concrete Floors Offers

Significant Savings Owners of the Liberty Center chose to install polished concrete floors in lieu of ceramic tile, saving the owner over $1 million dollars on the overall project budget.

O

pening to much fanfare in October 2015, the Liberty Center, located on I-75 between Cincinnati and Dayton, Ohio is a $350 million real estate development featuring retail, office and residential buildings. The sprawling campus includes the first enclosed mall to be built in the U.S. since 2007 and polished concrete floors plays a prominent part in the overall theme of the shopping center.

Joe McGovern, senior project manager at Hoar Construction (Birmingham, Alabama) was tasked

The owners chose solvent-based concrete dye colors, matched to the owner’s selections by Ameripolish: a natural polish meaning no dye was used, Repose Gray and Barcelona Beige.

Photo Credit: Jenny Eichholz

with guiding the mall construction, as well as finding solutions to a project budget which could have ballooned out of control.

“All of that came about in the context of a broader mission for Hoar Construction,” says McGovern. “Our client, Steiner and Associates, came to us and asked what we could do to find a way to make some budget cuts

50 Concrete Contractor | December 2015 | www.forconstructionpros.com/concrete

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for the project. They took that task away from the architect and put that on our team.”

The Liberty Center was designed to look like a rustic, old steel mill.

Visitors will notice exposed iron, bricks and steel forms. Installed on the exterior of the building is a 90 foot tall, faux smoke stack that will not be painted. Designers wanted the

smokestack to age naturally to create an early 1900s look. At the request of the owner, Steiner and Associates, McGovern and his team examined the design and offered some ideas—one of which was changing the specified use of over 100,000 square feet of ceramic tile to polished concrete throughout the public concourses of the mall.

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KEY PRODUCTS SASE Company Inc.

• SASE PDG 8000 30” Diamond Grinder • SASE PDG 9500 Plus 36” Diamond Grinder • SASE Edge Pro 180 • SASE BULL 1250EBS Dust Extractor • SASE BULL Pre-Separator • SASE SFS D2 Multi-Silicate Densifier • SASE Protect Plus Protective Coating Guard • SASE SFS SPR3 Oil, Water & Stain Inhibitor • SASE Diamond Tooling: Metal Bond, Hybrid Bond, Resin Bond, Diamond Impregnated “Trifecta” Burnishing Pads

Ameripolish

• Natural Polish • Repose Gray • Barcelona Beige

Skudo Floor Protection System Hi-Tech Systems

• HT-PE85 Polyurea Joint Filler (Relic Bronze, Gray and Porpoise) “All of that ceramic tile costs big bucks,” McGovern says. “We determined there were other ways to get a premium floor inside the mall, saving money and giving the project a better look for the overall theme of the building. Taking the standard, off-the-shelf option of ceramic tile would not fit into the desired theme.

The owner was agreeable to dye and polish the concrete floor which would also offer liberal design parameters.”

McGovern was told the design could contain no more than four colors and no tight, checker board patterns.

“Polished concrete offers design flexibility to designers,” McGovern notes.

“How much flexibility do you have with ceramic tile? Can you do circles?”

“With polished concrete, we are able to offer radiuses and diagonals.

If the contractor has to cut a tile to achieve a specific design, the price of the project starts to ratchet up and up and up,” McGovern says. “It was important for the owner and the

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Design flexibility and the cost savings convinced both parties polished concrete was the premium flooring choice.

Photo Credit: Jenny Eichholz

designers to know with a polished concrete option, I can chalk a line wherever I want, all day long, but the cost remains the same.”

Design flexibility and the cost savings convinced both parties polished concrete was the premium flooring choice. Within the context of the budget, the budget drives the design and the budget drives the project. Canceling the ceramic tile floor option gave designers a chance to be creative and save money.

“And that’s what every designer wants to hear. Designers will receive more design liberties with this system (polished concrete) than with the stale, old, ceramic tile.”

Supporting the Polished Concrete Industry Since 2009

JEFFCO CONCRETE Jeffco Concrete (Tuscaloosa, Alabama) was chosen as the contractor responsible for polishing over 100,000 square feet of concrete on two levels of concourse at the shopping center.

Jeff McCool started his contractor business in 1983. He began polishing concrete in 2000, transforming his contracting business into what it is today. Jeffco Concrete specializes in polishing concrete at schools, churches and large, industrial facilities. A resurgence of retail projects has helped Jeffco Concrete grow to performing work across 15 states around the country.

“You name it, we’ll polish it. We are a polished concrete contractor,” McCool proclaims.

McCool’s first machine was a HTC 800 HD and that machine is still on the floor, polishing. While the machine has been rebuilt several times, it’s still running and he now owns 34 grinding units in the company’s fleet.

With a 40,000 square foot warehouse, McCool employs seven crews to perform the work and he says polished concrete is 90 percent of the company’s volume per year.

JOIN T A S U Booth #S12653 Upcoming Events December 17 – Tradesman Webinar January 19-21 – Craftsman Certication February 2 – Concrete Polishing Luncheon & Forum

www.concretepolishingassociation.com (443) 249-7919 info@cpaa-us.org 38800 Country Club Dr. Farmington Hills, MI 48331

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McCool sums up his work perfectly, “If you place a perfect slab, I’ll polish you a great floor.”

McCool visited the jobsite in October 2014 and explained to the owner in detail about the process of polishing the floors. He says he discussed the floor maintenance options, the life cycle of the floor and of course, the cost.

Additionally, McCool helped coach McGovern and his team to develop an overall feel for what could be done with the floors. While ceramic tile was priced out at approximately $9.50 to $10 a square foot, a dyed and polished concrete floor was worth four dollars a square foot.

“We were looking at 107,500 square feet of concrete floor to be dyed and polished. Throw four dollars a square foot on that and it certainly gets an owner’s attention,” McGovern says. “Choosing a polished concrete floor offered a

Taking the standard, off-the-shelf option of ceramic tile would not fit into the desired theme. The owner was agreeable to dye and polish the concrete floor which would also offer liberal design parameters.

Photo Credit: Jenny Eichholz

phenomenal savings.”

Before long, Steiner and Associates wanted to visit McCool in Alabama to see some completed projects. “We walked around a lot of the jobs that I’ve performed and it was clear to me that the polished floor was going to fit nicely into what they were going to build,” McCool says. “But more importantly, choosing the polished floor saved the owners over $1 million dollars on the initial budget.”

The owners chose solvent-based concrete dye colors, matched to the owner’s selections by Ameripolish.

53,998 square feet of concrete received a natural polish meaning no dye was used, while 39,913 square

feet was dyed using Repose Gray and 13,589 square feet was dyed in Barcelona Beige.

Another challenge to the contractor was the slab for the floor was to be placed before the steel framework of the building was constructed. Therefore the slabs needed to be protected throughout the construction process.

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“Because the slab was to be polished, we didn’t want any damage to occur. We used a floor protection system from Skudo Floor Protection Systems and it was as good as it gets to protect the slab. Crews that came after the placement of the slab were driving lifts and building the shell of the building. Once the building was complete, we pulled up the protective covering and it was time for us to come in and polish the concrete.”

McCool offers a hat-tip to Lithko Concrete of Cincinnati, Ohio who placed and finished the slab. “They did an excellent job and it’s been a long time since we polished floors that good.”

2035 and that floor will look the same as it did the day the mall opened to the public in October 2015. And that’s an awesome selling point when pitching polished concrete floors to prospective clients.”

The low maintenance advantage of polished concrete floors was a huge selling point to the owners.

Photo Credit: Jenny Eichholz

A MAINTENANCE ADVANTAGE When speaking with his clients, McGovern says the maintenance advantage of polished concrete floors is a huge selling point. “The one aspect of ceramic tiles that always fails first are the grout joints.

The only way to save the floor is to fill the grouting joints and treat them with five to seven coats of sealant.

Daily maintenance with a cleaning machine will wear off the sealant at the joint. The grout joint will take on dirt, dust and debris and it will be visible,” McGovern explains.

Working as a team with McGovern, McCool reached out to the maintenance team at the Liberty Center to inform and educate them about how to maintain the floor once it was completed. For assistance, he also recruited his supplier, SASE Company Inc., who took the lead to work with their team and gave them everything they needed to maintain the floors.

“I tell all of our clients, there is maintenance required for a polished concrete floor, it is not maintenance free,” McCool says. “But, it’s a lot less maintenance than any other flooring system such as carpet, ceramic tile or VCT.” McGovern says the beauty of polished concrete floors is simple: “We can go to the Liberty Center in

See the PG 820 RC in action at World of Concrete 2016!

The Husqvarna PG 820 RC is our first remote-controlled floor grinder! It offers very high productivity, powerful performance, and outstanding ergonomics. The remote control is key on this machine. It enables the operator to move around the jobsite, correcting hosing, moving the dust collector, inspecting the floor, and preparing the next set of tools. This leads to increased productivity and less fatigue on the operator. Visit us at World of Concrete, Booth #O30166.

17400 West 119th Street • Olathe, KS 66061 • T 800-288-5040 • F 800-825-0028 Copyright © 2015 Husqvarna AB (publ.). All rights reserved. Husqvarna is a registered trademark of Husqvarna AB (publ.).

www.forconstructionpros.com/concrete | December 2015 | Concrete Contractor 55

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By Brad Burns

How to Properly Maintain Your Grinder

Your grinder is a capital investment, and it is important to get the best ROI from it. Learn how with these tips.

T

here are several levels of maintenance required; daily, weekly, monthly and annually.

Before we look at what should be done and when, remember: safety first. Use personal protective equipment when working on any grinder: safety shoes, eye protection, ear plugs, breathing mask and gloves are always a good idea.

Make sure to disconnect electrical supply or unplug the spark plug cord when performing any kind of service or cleaning on a grinder.

DAILY CARE Before using the grinder look at cables and hoses, paying attention to their general appearance, cracks, folds as well as plugs and connections. Replace any damaged cables.

Keep your equipment clean. After Check tool holder each use of the grinder, disconnect and grinding head power and brush or wipe off dust for cracks or other visible damage. and sludge (if grinding wet or using a Replace any built-in misting system). Tip back the damaged parts. grinder, remove tooling and wipe off the heads. Inspect plates and shroud, Photo Credit: HTC Professional Floor Systems make sure screws and bolts are in place and tightened.

Check the tooling for uneven or abnormal wear. This may indicate the tool holder is damaged.

Check tool holder and grinding head for cracks or other visible damage. Replace any damaged parts. It is a good idea to use manufacturer’s original parts, as they are made to strict standards and hence higher quality. If the grinder is equipped with remote control, remove any dust and residue from the radio control unit.

WEEKLY MAINTENANCE Weekly (or when needed), give the grinder a more thorough cleaning. Using a hose, rinse off dirt and grime.

Use a soft brush and soapy water if needed. Spray the heads and plates hard with the hose to remove dirt and other build-up. Do not use a high-pressure washer, as moisture may penetrate electrical components and damage them. The machines drive system can also be damaged by high-pressure washing.

Check the grinding heads. After removing tools, tip the machine back and run in mid-air at lowest speed. Look for heads significantly wobbling or oscillating. If they are, they

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Check for lower belt slip by leaning the machine back, grasp the grinding heads and try turning them toward each other. If you are able to turn them, a new belt is needed.

Photo Credit: HTC Professional Floor Systems

have been damaged and should be replaced.

Check for lower belt slip by leaning the machine back, grasp the grinding heads and try turning them toward each other. If you are able to turn them, a new belt is needed.

Check for upper belt slip by turning the large wheel in one direction or the other. If there is resistance the belt is OK, if it turns freely the belt needs to be replaced. Several manufacturers offer belt change kits, containing all the parts needed for belt changes.

Self-propelled grinders use a separate battery for the drive wheel motor. This battery charges continuously when the machine is connected to power. Since batteries deteriorate with age, visually inspect the battery. Replace it when needed.

GRINDING & POLISHING

DUST EXTRACTION

MONTHLY MAINTENANCE Set aside time once a month for a more detailed look at your machine. When doing the monthly (or 100 hour) maintenance, inspect fasteners as they may come loose from vibrations and require tightening.

Clean or replace the filter to the electrical box. Remove the grinding cover/shroud and check for damage. A damaged cover will make dust control and job site cleanup more difficult. Scrape and vacuum the parts that are normally covered by the grinding cover, and difficult to reach.

Check for upper belt wear by tipping the machine back, grabbing on to one of the grinding heads and apply downward pressure attempting to rotate the drum without allowing the head to spin. If the drum turns, and the head does not, the upper belt is worn and needs to be replaced.

Also check the seals on the shafts on which the upper belt runs. Replace if necessary.

Test run the machine in tilted back position, listen for any dissonance from the bearing. Replace them as needed.

MIXING & OVERLAYS

COLOR & CHEMICALS

MAINTENANCE

REPAIR WORK & EDGING

MAINTAINING PROPANE POWERED GRINDERS Electric motors require minimal maintenance, but if the grinder is powered by a propane engine, this needs additional attention. When working on propane engines, it is important to remember to bleed off the pressure on lines or valves before removing components. Additives in the engine oil get depleted over time and with use, change the engine oil at recommended intervals.

Replace the spark plug when you change the oil. Make sure you use the right replacement plug, screw it in place without over-tightening, and reconnect the spark plug wire.

Clean or replace the air filter once or twice a year. Let it air dry thoroughly before replacing.

Finally, get a professional tune up once a year. All major manufacturers have authorized service shops, where maintenance, repairs or rebuilds can be done.

Ed. Note: Brad Burns is the Technical Director at HTC Professional Floor Systems, www.htc-floorsystems.com/ www.htc-twister.com

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www.forconstructionpros.com/concrete | December 2015 | Concrete Contractor 57

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12/7/15 9:36 AM

THE LAST PLACEMENT: BACK TO BASICS

10

for Bidding Concrete Polishing Jobs tips

Use these tips to help better determine costs before you turn in your bid to a general contractor or home owner.

A

polished concrete floor project can be a tough job to bid because of the many variables a contractor needs to consider — labor, abrasives, the floor itself, just to name a few. As such, polishing contractors need to be prepared and ready to adjust for variables on the jobsite. It also makes defining a job’s cost upfront an even greater challenge.

1

REPAIRS

Planning for repairs can be one of the most challenging issues a contractor will face when bidding an existing floor project. Always remember, sometimes toppings like carpeting and tile were put on a floor because the concrete was bad in the first place.

Spall repairs can cause unforeseen costs and challenges.

Spall repairs required beyond the allowance in the bid are priced out in an addendum to the bid, as are necessary crack repairs and spalling along joints.

2

UTILITIES

Make sure power in the correct voltage will be available on site. If it is not, the power for your equipment will need to come from portable generators. The same goes for water.

3

CONSTRUCTION/ JOB SCHEDULE

Find out how much time you have to perform your work and during what times of the day you can do it. If you are working under a tight schedule, or working a job on an existing building still being used for business, you may find yourself confined to do your work nights and weekends. If that is the case, you will need to pay your employees a premium and consider those extra labor costs in your bid.

A job schedule, i.e., a plan that lays out when certain trades will be in a building and who they will be working around. What is especially important to pay attention to is two things: floor protection and walls. You may have to arrange for floor protection before and/or after your polishing job. Be sure it is clear in the bid who is responsible for installing floor protection and who will pay for it. You will also need to know if you will be polishing before or after the walls are built.

4

EDGES AND HANDWORK

Your edging costs should include handwork necessary to grind and polish steps, embeds like floor drains and pipes, or any other spot where you stop your floor grinder and have to pull out smaller tools.

Ask the general contractor for the as-built drawings of the structure.

The drawings will give reflect changes that were made to the original plans and give you the most accurate look at the building.

5

SAMPLES

Make it clear to your clients that samples and mock-ups are not free. Charging helps you attract the clients who are serious.

6

ABRASIVES

There are several factors that will affect your abrasives costs, including hardness of concrete and the number of steps you are required to perform throughout the grinding and polishing process.

7

CUT

Cream, salt and pepper, or aggregate – if the desired cut of the floor is not clear in the specifications, make sure it is before you submit your final numbers on the job.

8

FLOOR FLATNESS

On new construction projects, ask for a floor flatness report before you start grinding. This way you know exactly what FF and FL numbers you will be dealing with. These numbers can affect your labor costs and diamond expenditure.

9

JOINTS

Most specifications will require the polisher to do joint work on the floor. While a saw cut control joint might be 1/8-inch wide, a construction joint can be ½ inch wide. Your joint filler material needs will vary depending on the types of joints in your floor. That material isn’t free; plan for that amount in your bid.

10

DISPOSAL

Take a look at you job and decide if it will be a wet grind or dry grind. You will need to factor into your bid equipment and costs for dust control or slurry disposal.

Ed. Note: If you have a topic you’d like to see in the “Back to Basics” column, please drop me a line at Rolson@ACBusinessMedia.com.

58 Concrete Contractor | December 2015 | www.forconstructionpros.com/concrete

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