Concrete Solutions by Landscape Structures

Concrete Solutions

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Get flexible with concrete Over the last few years, many playgrounds have included Landscape Structures rock climbers, mushroom steppers, log steppers and other concrete components as independent play items or access points to a playstructure. But did you know that concrete can be used in and throughout playstuctures as a flexible design medium to give your playground a unique look?

Safe, durable, high-value concrete pieces can provide multiple uses.

From an entrance feature to an anchor statement. From a freestanding thematic element to an integrated part of a post-and-deck system, Landscape Structures has comprehensive design and fabrication capabilities to pump up the design and play value of your playground.

Before launching our own concrete operations, we went outside of our industry and researched state-of-the-art U.S.-based manufacturers. We immersed ourselves in concrete industry best practices, then developed our own knowledge base and proprietary systems. Along the way we assembled an experienced, multi-disciplinary design and manufacturing team who will work with you throughout the entire process, from initial concepts to installation.

Discover how you can fully utilize the design flexibility of sculpted concrete to create a one-of-a-kind playground that’s unique to your vision.

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Commitment to concrete In 2006, we sprayed our first Glass Fiber

batch plant and admixture management

Reinforced Concrete (GFRC) panel in-house.

systems, computerized steam-curing tents,

Since then, we have applied industry best

and specialized prep and paint booths. This

practices, our own proprietary systems and

large-scale investment allows us to manage all

our extensive custom design capabilities

facets of our concrete play and site furnishing

to make Landscape Structures the premier

products internally, reinforcing our commitment

concrete manufacturer for playgrounds.

to make the highest quality kid- and

With a concept designer at the helm, we began designing extraordinary personalized

We’ve found that manufacturing within a

and custom pieces in 2007. Then our entire

controlled factory environment is not only the

artistic team created the Play NaturallyTM line,

right approach for providing superior quality, it

incorporating nature-inspired, life-like themes

also reduces our environmental impact. From

and highly detailed discovery elements

the beginning, we’ve recycled our process

into concrete.

water, and controlled waste water and storm

Today, our dedicated concrete operations building features a design studio and mold-making area along with cutting-edge processing equipment such as computerized

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community-friendly concrete products.

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water runoff. Even our concrete uses reclaimed materials. In total, we have more than a dozen green, energy-saving features designed into the building. Learn more on page 14.

Design capabilities The Landscape Structures design team

flora and fauna like seashells, trees, fossils,

includes a broad range of play specialists:

“critters,” and more. Kids love the extra thrill

professional artists with formal art training,

of spotting hidden educational or discovery

certified playground designers, and

elements. The unique shapes and textures

experienced structural and design engineers.

possible with sculpted concrete allow kids of

Together, they share one mission: to develop

all abilities to experience and learn about the

creative, kid-friendly designs while ensuring

natural world, enhancing their overall

each playground meets all safety and

play experience.

accessibility requirements.

Concrete is also an ideal medium for other site

Whether you’re looking for a fun and

amenities such as signs, iconic entry features,

educational experience or an outrageous

sculptures, seats and tables, sand and water

design that’ll keep kids coming back, concrete

play features, and discovery trail elements.

is the ideal medium for turning ideas into real playgrounds. It offers an amazing range of texture, color, scale and flexibility, both as independent, freestanding elements and integrated into post-and-deck structures.

Let us partner with you to help generate fun, unique and creative concepts. Our diverse team can handle virtually any design request, from a barely defined idea to a detailed rendering—or anything in between. Part of

Consider incorporating elements specific to

the fun in designing a playground is working

your local history—famous personalities or

with an expert partner who wants the same

events, celebrated geography, even regional

things you do.

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Concrete 101 Modern concrete is a blend of: 1) Portland cement, 2) aggregates, 3) water, 4) engineered fibers and 5) other additives specific to the application.

1) Portland cement is made by kiln-firing limestone and other materials to make a chemically active substance that’s prepared to interact with water and other chemicals during mixing and curing.

2) Aggregates are a key component in creating structural strength in concretes.

Depending on the type of concrete design, they can vary in size from microscopic particles and sands to pea gravel, rock and even 3"-4" stone.

3) Water primarily acts as a chemical component that allows Portland cement to properly hydrate and cure.

Its secondary role is to create a useable, semi-liquid mix that can be pumped or poured when molding, spraying or sculpting.

4) Engineered fibers are added to create stronger concretes.

5) Other chemical additives are also used to manage workability and cure times, increase freeze/thaw protection, improve water resistance and other key characteristics.

Working with concrete Concrete is something we all take for granted, but it’s not as simple as it seems.

Control of this complicated process requires exact proportioning, careful mixing, controlled temperatures of all ingredients, managed working time (the period when the concrete can be sprayed, poured, troweled or sculpted), and protection and care during curing.

Complete cure can take weeks or months, with residual curing occurring indefinitely. continued on next page

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Concrete 101

(continued)

For these reasons, Landscape Structures manufactures all of our concrete products within the controlled conditions of our concrete operations building. We have the expertise, technology and infrastructure to manage all of these variables to create high-quality, repeatable products for you.

Types of concrete Glass Fiber Reinforced Concrete (GFRC) is a composite material consisting of a cement-based matrix surrounding glass or polymer reinforcing fibers. The fiber adds tensile strength while the cement matrix locks the fibers in place and provides great compressive strength. Other components improve the workability during manufacturing, enhance curing, and increase the overall strength and durability of the product. Our proprietary formulations allow extraordinary details to be captured either in a mold or during hand sculpting. prayed GFRC—Sprayed into molds using •S specialized equipment and highly trained operators. Typically used to create larger scale panels and capable of intricate surface detail.

• Sculpted GFRC—Hand-sculpted onto steel frames. Used for sculptural elements such as 3D figures, animals and highly customized designs.

Wet-Cast is similar in appearance to ready-mix concrete and is always placed and cured in a mold. Added ingredients and processing provide freeze/thaw resistance and increase workability, strength and crack resistance. Capable of replicating tiny details, wet-cast concrete is generally used for smaller scale, solid, durable objects. It’s sustainably engineered using flyash (a waste product of coal-fired electric power generation) to replace some of the cement in the mix design.

•M old design—We use molds to create high quality, repeatable products. The mold liner features all of the precise detail—textures, fossils and creatures— that the concrete will conform to and reproduce in mirror image.

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The sculpted GFRC process Depending upon a project’s complexity and the customer’s needs, some of these steps may be optional.

The timing for each step is an approximation and can vary from project to project.

C.

Step 1.

Initial Concept Usually a pencil sketch based on provided criteria; includes approximate sizes, construction details and reference photos. (Figure A) Timing: 1-5 days Step 2.

Clay Scale Model Further illustrates the dimensionality and proportions of the sculpture. (Figure B)

Figure a

Timing: 1-3 days Step 3.

Shop Drawings Concept drawings and models are used to develop shop-ready drawings that will act as guidelines when creating each piece at full scale.

Timing: 1-5 days Step 4.

Steel Framework Using standard fork pocket steel tubing, a sculpture base is welded together. Then laser cut steel plate, tubing and 3/8” rebar is shaped and welded into a structural skeleton. (Figures C and D) Timing: 1-5 days per sculpture Step 5.

Steel Mesh To ensure durability, the rebar framework is covered with 18-gauge perforated metal sheeting, which is typically cut and formed to shape as it is welded into place.

(Figure E) Timing: 2-3 days

Figure B 10

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Figure D

Figure C

Step 6.

Concrete GFRC Applied by hand, GFRC concrete is pushed through the perforated sheeting. Two to three 1/4� layers continually build up the surface and are artistically sculpted.

The ASTM-certified probes are used to assure each sculpture meets safety requirements.

Timing: 1-3 days

Figure F

Step 7.

Finish Concrete A final 1/4" layer of non-fiber concrete is applied to the entire sculpture. Using textural stamps, carving tools and brushes, the finish coat is manicured into the final detailed sculpture. (Figure F) Timing: 1-2 days Step 8.

Concrete Curing The sculpture is cured in a steam tent for a minimum of four days.

Next, it is cured in a humidity-controlled environment, then air-dried prior to finish.

Timing: typically 14 days

Figure E

Figure G

Step 9.

Concrete Prep The entire sculpture is sanded down using wire wheel grinders to remove all sharp edges and to polish various details.

Any blemishes are patched, and other construction details are installed.

Timing: 2-3 days Step 10.

Paint A concrete paint is spray-applied in layers.

Brushwork and antiquing washes further develop the finished look.

(Figure G) Timing: 1-3 days Step 11.

PACKAGING Photos, installation details and specific hardware are boxed along with any custom pallets, strapping or installation elements.

Timing: 1-2 days

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Maintenance Concrete is very durable and will provide years of service. Like the rest of your playground equipment, it does require periodic inspection and maintenance. The keys to keeping your concrete looking great and performing well are periodic inspections and managing problems while they are small.

Cracking Hairline cracking is nearly unavoidable in concrete and should be expected over time. The vast majority of cracks are superficial, pose no risk, and do not impair the usability, appearance or safety of the piece. Landscape Structures can provide the materials and instructions to assure maintenance personnel can successfully touch up any objectionable cracks.

Efflorescence In some situations, usually in high moisture areas, concrete may exhibit a chalky white residue on the surface. This is a result of moisture moving through the concrete, carrying dissolved salts to the surface. Efflorescence generally occurs close to surface cracks or depressions in the surface.

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Although unattractive, these deposits do not impair the usability or safety of the concrete structure. Caught early and treated right away with a stiff bristle brush and clean water, you can remove most deposits.

Paint Finishes Naturally, paint finishes are subject to lots of wear and tear since most of our concrete pieces are designed as climbing elements. Shoes, branches, bikes, toys, and other playground abuses can chip and remove paint. Landscape Structures has the materials and instructions to help keep your paint finishes looking great. We also record the details of all custom finishes to ensure they can be easily maintained over time.

Always keep in mind that minor repairs may look worse than the original problem. If you have any questions about how to keep your concrete playground structures looking their best, please contact Landscape Structures.

Contact your local playground consultant today at 888.438.6574 to learn more. Or visit playlsi.com.

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Our green story Our concrete commitment goes beyond the creation of great looking and high performing concrete products. Early on, Landscape Structures made the commitment to avoid environmentally hazardous or difficult to manage materials whenever possible. We have consistently avoided conventional staining and coloring techniques using acid washes. And we built our dedicated concrete operations building to include a variety of features that support the Landscape Structures sustainability commitment.

Plant air management system uses variable speed fans to balance the pressure and air-flow inside the building, maximizing efficiency; remote monitoring allows changing set-ups and monitoring performance.

Plant air is captured, filtered and re-used for smoke, fume and dust management, rather than vented to the exterior.

Batch plant silos have vacuum dust management systems in place to prevent releasing dust emissions into the atmosphere during filling operations.

Storm water management

Recycle water system otable water usage reduced to an average of •P 600 gallons/day for ALL uses (batch plant, boiler steam generation, paint dilution/cleaning, domestic, make-up water)— the same approximate daily water usage of an average family of four • Recycled water is used at approximately 3,000 gallons/day for cleaning, misting tents and wash water Compressed air system • Compressor electric motor is ultra highefficiency (highest efficiency compressor at Landscape Structures) • This variable displacement compressor modifies its internal geometry according to demand, permitting high-efficiency operation over a broader range of demand • Large receiver tank reduces cyclic loading on compressor Plant lighting is high-efficiency, high-bay fluorescent lighting with zone controls; lights shut off automatically when no one is in the zone for 30 minutes.

Office lighting is on occupant-sensing switches; lights shut off automatically when no one is in the room.

Plant heating uses gas-fired make-up air units to satisfy paint booth requirements; occupant comfort is assured with infra-red heaters that heat objects (people, work pieces, tools), not the air.

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• Managed through an engineered storm water system, while surface run off is controlled via engineered erosion-prevention systems • All waste bins are covered containers or stored under engineered tents (all rain/snow tight) • Outside aggregate bins are under engineered tents (rain/snow tight) • No unfinished product is allowed to be stored outside to prevent leaching of materials into uncontrolled run-off Batch plant is configurable for desired batch size.

Our goal is to produce NO WASTE by mixing only what is needed as needed.

All process liquids in 55 gallon containers (or more) are in secondary containment in case of leaks or punctures.

Exterior lighting is designed to distribute light to the ground and prevent “junk light” from unnecessarily illuminating the night sky.

Air conditioning systems have an “Economizer” feature that uses cooler ambient air (when available) rather than running the AC compressor.

Office heat/cool systems are computer controlled, and idle during non-business hours and over weekends to conserve energy.

Glossary Admixture Substance added to a concrete mix to modify its properties.

Aggregates Ranging in size from microscopic particles and sand to rocks and stone, aggregates are added to create structural strength in concretes.

Cement Portland cement is the mix of chemically active limestone and other materials that react with water and aggregates to solidify into concrete.

Concrete Broadly used to describe some form of cement, water, aggregates and admixtures.

Curing The process of setting and hardening concrete under controlled conditions of humidity and temperature.

Custom Concrete A concrete sculpture or structure designed and manufactured to the exact requirements of a specific customer.

Delamination The flaking or chipping of paint usually most common in high moisture environments; generally associated with cracking.

Efflorescence The moisture-borne, chalky white salts that appear on the surface of concrete and masonry.

GFRC Glass Fiber Reinforced Concrete Refers to any concrete which contains a relative high percentage (more than 1 percent by weight) of fiber-reinforcing media.

Sprayed GFRC GFRC that is applied to a mold or sculpture via a spray gun that combines concrete and fiberglass and uses compressed air to eject the material in a controlled pattern.

Sculpted GFRC GFRC that is applied and finished by hand.

Wet-cast Concrete A form of fiber-reinforced concrete that is pourable and generally used in molds.

Warranty Landscape Structures is committed to making longlasting, high quality products. We stand behind all of our concrete products with an industry-leading warranty and a promise to make things right for you.

Concrete components shall have a 10-year limited warranty against structural failure due to natural deterioration or manufacturing defects. Minor chips, hairline cracks and efflorescence are inherent in concrete products and are not covered by warranty.

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Better playgrounds.

Better world.

TM

Since 1971, Landscape Structures has been committed to enhancing children’s lives by fostering and creating inspiring play experiences while honoring the environment. We create innovative playground equipment to inspire children to grow strong bodies and minds so their futures remain bright. And to further ensure a better tomorrow, we are sensitive to the environment through manufacturing practices that minimize our impact on the earth. Our goal from day one has been to foster healthy children playing in healthy communities year after year, generation after generation.

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