Taking the Mystery out of Mix Design in Part 1 of 2, Ken Hover Covers the Three Factors That Deﬁ Ne a Concrete Mix

INSIDE: CONCRETE SURFACES November/December 2019

An Ofﬁ cial Magazine of World of Concrete

Taking the Mystery Out of Mix Design In Part 1 of 2, Ken Hover covers the three factors that deﬁ ne a concrete mix. Pg 19

Pumping Dry Materials Pg 29

Installing a Thermal Break Pg 35 ONE-PASS POWERHOUSES

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CONTENTS November/December 2019 / Volume 64 / Number 7 19

Photo: Votorantim Cimentos/Prairie Materials

FEATURES DEPARTMENTS

19 Taking the Mystery Out of Mix Design 5 Insider Information CS-41 Tie a Yellow Ribbon Learn how the various ingredients in a Come to WOC Again Sometimes the concrete mix come together in Part 1 of this only way to ﬁ x two-part article. 10 Projects That Rock a bad polishing job A Formwork Challenge is to start over. 29 Material Placement Made Easy Fill and subgrade materials can be air-pumped 12 Business CS-45 Getting Consistent into inaccessible locations. Your Company’s Culture is Critical Results on Polished Concrete Overlays 35 Insulating Concrete Balconies 16 Uncommon Sense Follow these three steps for Structural thermal breaks are increasingly Leading Our Laborers a successful installation. used to save energy and eliminate cold ﬂ oors, condensation, and mold growth. 56 Innovation Can Innovation Solve the Labor Shortage?

IN THE NEXT ISSUE OF CONCRETE • The Most Infl uential People in the industry, plus Four Under Forty • Robotics in Concrete Construction CONSTRUCTION • Keeping Concrete Mixes Pumpable

ON THE COVER: Designing concrete mixes is a balancing act between achieving the hardened properties of strength and durability while still having a placeable, workable mix. Photo: Votorantim Cimentos / Prairie Materials

CONCRETE CONSTRUCTION (ISSN1533-7316) is published 6 times per year (January, April, May/June, July/August, September/October, November/December) and once digitally (February/March) and is copyrighted ©2019 by Hanley Wood, 1152 15th Street NW, Suite 750, Washington, DC 20005. Postmaster: Send address changes to Concrete Construction, PO Box 3494, Northbrook, IL 60065 Canada Post Registration #40612608/G.S.T. number: R-120931738. Canadian return address: IMEX, PO Box 25542, London, ON N6C 6B2. Technician Aggregate Testing Technician Aggregate/Soils Base Technician Concrete Construction Construction Special Inspector Concrete Quality Technical Manager Concrete Transportation Special Inspector Tilt-Up Supervisor Tilt-Up Technician Shotcrete Nozzleman Shotcrete Nozzleman- in-Training Masonry Field Testing Technician Masonry Laboratory Testing Technician Adhesive Anchor Installer Field Testing Technician Flatwork Finisher Specialty Commercial/Industrial Finisher Specialty Commercial/Industrial Technician Strength Testing Technician Laboratory Testing Technician Aggregate Testing Technician Aggregate/Soils Base Technician Concrete Construction Special Inspector Field Testing Concrete Quality Technical Manager Concrete Transportation Special Inspector Tilt-Up Supervisor Tilt-Up Technician Shotcrete Nozzleman Shotcrete Nozzleman-in-Training Masonry ch Flatwork Finisher nician Masonry Laboratory Testing Technicia Adhesive Anchor Installer Field Testing Technician Flatwork FinisherACI Specialty CERTIFICATION Commercial/Industrial Finisher Specialty Commercial/Industria Technician Strength Testing Technician Laboratory Testing Technician Aggregate Testing Technician Aggregate/Soils Base Technician Concrete Construction Special Inspector Base Technician Transportation Special Inspector ConcretePROGRAMS Transportation Special Inspector Tilt-Up Supervisor Tilt-Up Technician Shotcrete Nozzleman Shotcrete Nozzleman-in-Training Masonry Field Testing Technician Masonry Laboratory Testing Technicia Adhesive Anchor Installer Field Testing Technician Flatwork isher Shotcrete her Commercial/Industrial Finisher Specialty Commercial/Industrial Technician Strength TesNozzlemanian Laboratory Testing Technician Aggregate Testing Technician Tilt-Up Soils Base Technician Concrete Construction Special Inspector Associate Concrete TransSupervisor Inspector Concrete Transportation Special Inspector Tilt-Up Supervisor Tilt-Up Technician Shotcrete Nozzleman Shotcrete Nozzleman-in-Training Masonry Field Testing Technician Masonry Laboratory Testing Technician FF vvv Adhesive Anchor Installer Field Testing Technician Flatwork ty Strength Specialty ialty Commercial/Industrial Finisher Specialty Commercial/Industrial Technician Strength Testing Technician Concrete Testing Technician Aggregate Testing Technician Aggregate/Soils Base Technician ete Construction Special Inspector Concrete Quality Technical Manager Concrete nician Special Special Inspector Tilt-Up Supervisor Tilt-Up Technician Shotcrete Nozzleman Field Testing otcrete Inspectoran-in-Training Masonry Field Testing Technician Masonry Laboratory TTesting Technician Adhesive Anchor InstallerWith Field 26 Testingprograms Technician (and several Flatwork more in development), Finisher Specialty the Commercial/Industrial Finisher Specialty Commercial/IndustrialAmerican Concrete Technician Institute has Strengtha certification Testing program Technician to Laboratory Testing Tilt-Up Aggregate Testingsatisfy anyTechnician number of Aggregate/Soils concrete specialties Base that Technicianyou’ve been Concrete Construction ecial Technicianssociatethinking Concrete about. Transportation Offering certifications Special around Inspector the world Concrete Transportation since 1980; learn how you can become ACI certified at Special Inspector Tilt-Up Supervisor Tilt-Up Technician Shotcrete Nozzleman ShotAdhesive Anchor www.concrete.org/certification. in-Training Masonry Field Testing Technician Masonry Laboratory Testing Technicia Installer Anchor Technician Flatwork echnician Flatwork Finisher Specialty Commercial/Industrial Finisher Specialty Aggregate Testingtrial Technician Strength Testing Technician Laboratory Testing TechnicianTechni Testing Technician Aggregate/Soils Base Technician Concrete Construction Special Inspector Concrete Quality Technical Manager Concrete Transportation Special Inspector Tilt-Up Supervisor Tilt-Up Technician Shotcrete Nozzleman Shotcrete Nozzleman-in-Training Masonry Field Testing Technician Masonry Laboratory Testing Technician Adhesive Anchor Installer Field Testing Technician Flatwork Finisher Specialty Commercial/Industrial Adhesive Anchor Installer Industrial cian Strength Testing Technician Laboratory Testing Technician Aggregate Testing Technician Con Aggregate/Soils Base Technician Concrete Construction Special Inspector Concrete Quality T Inspector Tilt-Up Supervisor Transportation Special Inspector Shotcrete Nozzleman-in-Training Shotcrete Nozzleman Tilt-Up Technician Shotcrete Nozzleman-in-Training Masonry Field Testing Technician Adhesive Anchor Installer Masonry Laboratory Testing Technician Field Testing Technician Flatwork INSIDER INFORMATION

Come to WOC Again William (Bill) Palmer Jr., P.E., FACI IT’S THAT TIME OF YEAR AGAIN—SHOWTIME. The 2020 World of Concrete (Feb. 3–7) promises Editor at Large some interesting new events and features in addition to the already great continuing [email protected] offerings. Here are a few things you won’t want to miss: Twitter: @wmpalmer • Polished Concrete Luncheon (Tuesday): Power trowels are opening a huge new market for polished concrete, since they can work large areas in a fraction of the time of traditional grinders. Learn more about this from a panel with Jessica Ledger- Kalen, Royale Concrete; Ryan Klacking, Syncon Inc.; Shawn Halverson, Surfacing Solutions Inc.; Ben Wiese, Multiquip; and Neil Roach, Redimere Surface Solutions. • Quality in Concrete Slabs Luncheon (Wednesday): Learn more about the newest ideas in curing for everything from industrial slabs to decorative concrete from this expert panel: Clark Branum, Diamatic USA, chair of ACI-ASCC Committee 310, Decorative Concrete; Dave Hoyt, Curecrete, chair of ACI Committee 310, Task Group on Curing; Scott Tarr, North S. Tarr Concrete Consulting; and Bob Harris, Struc- tural Services Inc. and the Decorative Concrete Institute. • Robotics Live: The robots are coming to your jobsite and sooner than you think. Check out this new event that will include the Tybot, an autonomous robot that ties The robots bridge deck rebar mats, and MudBots, a 3D printer that can build a concrete home in hours. (In the North Hall.) are coming • Decorative Concrete Live: This year, Bent Mikkelsen’s crew will focus on using insulating concrete forms, constructing urban water features, placing textured sooner than walking surfaces, selecting colored exterior coatings, forming curved surfaces with fabrics, and building concrete outdoor furniture. (South end of the Silver Lot.) you think. • Zero Emissions Live: This showcase area will focus on battery-powered tools and equipment. The batteries have gotten so much better that this is the quieter and cleaner future of construction. Participating companies are Wacker Neuson (vibrators and soil compacters), Green Machine (mini excavators, light towers, and batteries), and Ecovolve (electric dumpers). • Advanced Concrete Plants (Monday): Concrete producers will discuss the challenges of permitting and building new plants for major construction markets, along with the rapid rise of technology tools that are reshaping every aspect of operations.

Sorry, Jon! Through a screw-up that was completely my fault, Jon Hansen, who runs the concrete parking lots program for the National Ready-Mixed Concrete Association, was not listed as a co- author on the article “Perfect Industrial Pavements” in the September-October 2019 issue. Jon contributed a large portion of this article and has been relentless in his efforts to promote concrete for parking—and it’s gaining strength. Millions of square feet are being placed in concrete instead of asphalt, both in new construction and as overlays, and the NRMCA Design Assistance Program is designing more lots than ever. Sorry, Jon, and keep up the great work! www.concreteconstruction.net CONCRETE CONSTRUCTION November/December 2019 5 Editor at Large, Commercial Construction William (Bill) Palmer Jr., P.E., FACI • [email protected] Senior Graphic Designer Anna Abbinante • [email protected] Production Manager Stephanie Fischer • [email protected] Ad Production Coordinator Terry Rinella • [email protected] Group Director, Audience Marketing & Circulation Chris Lustan • [email protected] Audience Marketing & Circulation Manager Diana Turco • [email protected] Vice President, Marketing Matthew Carollo • [email protected] Senior Vice President, Sales – Pool & Concrete Construction Group Ray Giovine • [email protected]

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Concrete Polishing Luncheon & Forum Quality in Concrete Slabs Luncheon & Forum February 4, 2020 | 11:30 am–1:30 pm February 5, 2020 | 11:30 am–1:30 pm Presented by CONCRETE SURFACES magazine in cooperation with the Presented by CONCRETE CONSTRUCTION magazine in cooperation with the ASCC Concrete Polishing Council. American Society of Concrete Contractors.

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Topic: Polishing with Power Trowels—Can it replace planetary Topic: Alternative Concrete Curing Methods—Hard-Troweled grinding equipment? Versus Decorative Planetary grinders are the standard equipment used to create beautiful polished How a concrete slab is to be used can dictate how it is cured. There’s not even concrete fl oors. But recently, there’s been a move to equip riding power trowels an ASTM standard test to know if a concrete fl oor has been adequately cured. with diamond tools and use them to polish concrete fl oors, and for good Do hard-troweled surfaces even need to be cured? What about industrial slabs reason—a power trowel can polish 5 times faster. But can a power trowel polish that are to be polished? At this luncheon, concrete fl oor and decorative concrete a concrete fl oor to the same level of refi nement as a conventional grinder? Will experts will compare and contrast the current curing methods and products for polishing with trowels replace conventional polishing or does it simply produce hard-troweled fl oors versus those used for decorative concrete. a different kind of polished concrete fl oor and open different markets? An expert panel will answer these questions and more. PROJECTS THAT ROCK

A Formwork Challenge Simulating a massive limestone château foundation.

BY BILL PALMER || THE COLEBROOKDALE RAILROAD Preservation Trust in Pennsylvania has been working to bring back to life a beauti- Aluminum-clad formwork panels with the nailed-on furring strip and window blockouts waiting ful and historic railroad line. As part of that to be covered with aluminum. effort they are building a new station in Pottstown’s Memorial Park in the center of a Rust Belt town working hard to reinvent itself. The station needed to inspire and uplift the community and set the stage for an experience visitors would ﬁ nd magical. They chose a design that turned out to be a challenge to build, especially the foundation walls meant to simulate the limestone block foundations of European châteaus. To account for the vibrations of passing trains and support the weight of an 80-foot clock tower, a massive reinforced concrete foundation was deemed necessary. The footing alone required 150 cubic yards of concrete with 28 tons of #7 and #8 rebar. Getting consolidation within the tapered walls, 2 feet thick at the base, was challenging. Local ﬁ rm Drumheller Construction The château and foundation walls will be coated with synthetic stucco to make the whole accepted the job and carefully formulated building appear to be limestone. a plan. Drumheller’s owner Jody Zeleznick worked with local carpenters to create custom wood forms clad in aluminum sheeting that provided the polished limestone effect the owners sought. But with 2-inch hori- zontal grooves formed with ripped lumber, Zeleznick was concerned about stripping, so he covered the furring strips with aluminum after they were nailed to the forms. The forms stripped cleanly. “My men put a lot of thought into the forming and all the aspects of the job,” Zeleznick says. “It was small but one of the most challenging projects I’ve had in my 45 years of building with concrete. I am very glad Drumheller Construction was part of it.” CC

10 November/December 2019 CONCRETE CONSTRUCTION AAchievechieve DDurable,urable, Long-LastingLong-Lasting RResultsesults oonn YYourour BuildingsBuildings aandnd SStructurestructures

RRepair,epair, rrestore,estore, andand extendextend tthehe llifeife ooff cconcreteoncrete sstructurestructures wwithith RRapidapid SSetet ccementement pproducts.roducts. UUsese fforor vvertical,ertical, ooverhead,verhead, aandnd hhorizontalorizontal aapplications.pplications.

AAdvantages:dvantages: FFASTAST SStructuraltructural sstrengthtrength inin oneone hourhour SSTRONGTRONG HHigherigher sstrengthtrength ffaster,aster, forfor shortershorter closureclosure ttimesimes DDURABLEURABLE LLongeronger llastingasting cconcreteoncrete

AAsksk hhowow oourur pproductsroducts aandnd ffieldield ssupportupport ccanan hhelpelp yyouou easilyeasily ccompleteomplete pprojectsrojects ffaster.aster. CCTScement.comTScement.com 8888-307-273588-307-2735

VVisitisit uuss aatt BBoothooth ##S10405S10405 BUSINESS

Wally Adamchik [email protected]

Your Company’s Culture is Critical To increase your profits and employee retention, build bridges inside your organization.

CREATING A GREAT culture at your con- happy employees is feeling safe at work. able to maintain a reasonable work- struction company could be your best Every contractor will say that people life balance.” Only 50% of field leaders profit strategy. There is a direct correla- are our most important asset—but talk said yes to this, versus 83% of office tion between great workplace culture is cheap. While 90% of all respondents personnel. Or let’s look at the response and increased profitability. Through reported that safety is a top priority, to whether company leaders live by the my company, FireStarter Speaking and that was only true of 85% at the execu- core values of the organization. Only Consulting, we recently talked to several tive level. But 97% of office operations 62% of field leaders agreed to that while hundred construction professionals and 93% of field supervisors responded 83% of office personnel did. across all trades about leadership and that safety is a top priority. The bad The research confirms that having culture at their firm. We didn’t ask, news came when we asked about safety a close friend at work increases loyalty “Are you having trouble finding people?” execution. Only 68% of field supervisors and commitment. So it’s alarming that Instead, we asked, “Are you happy at said they consistently work safely. That’s only 50% of field leaders could say that work?” and “Do you feel trusted?” approximately 1 in 3 field supervisors they have a close work friend, while The answers to these questions are who admit they don’t prioritize the safety 83% of office staff could say the same. strongly related to employee motivation of their employees. Things are slightly The causes of this chasm are debat- and retention. Generally, any time we better in the office, with 78% reporting able but it is undeniably detrimental to talk about retention, the conversation that they consistently work safely—but profitability and productivity. quickly moves to money. But 77% of the gap between what is said and what Musician Sheryl Crow sang that the professionals interviewed for this is actually done is alarming. a change would do you good, but the survey reported that their pay is fair The gap between field and office majority of survey respondents said for the work they perform, so more persists in other areas as well, and the attempts at change often fall short. money is not the answer. research confirms that the divide is get- On this question, company executives Another factor that helps create ting worse. This cultural divide creates confessed to these failings at a level of distance and ten- 73%. If leadership is about change for sion. The differ- better results, it is troubling that three- ence in perception quarters of senior leadership (those who between project come up with the idea and whose job management in it is to spearhead the change) say their the office and field efforts fall short. This signifies a huge supervision on the opportunity for those who can crack the jobsite is stark and code on implementing change. Here’s provides a major the bottom line: It takes longer than opportunity for you think, and it requires a significant dialogue, collabo- personal investment from leaders to ration, and unity. sell change, but implementing change Any effort to bridge remains the fastest way to build trust, this chasm is leverage relationships, and troubleshoot worthwhile. potential problems. Take the survey All is not lost, however, and you ADOBE STOCK | THEKOB5123 question: “I am can find people who will step up. When

12 November/December 2019 CONCRETE CONSTRUCTION www.concreteconstruction.net BOBCAT.COM/ATTACHMENTS

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OFFICE OPERATIONS VERSUS FIELD SUPERVISION inside their organization and ask these OFFICE FIELD questions to see how they compare. You need to reach the point where more 81% I have a close friend at work 50% than 90% of your employees will re- 83% I have confidence in leadership of this organization 68% spond (willingly and anonymously) that 81% Company leaders live by the core values of the organization 62% the company’s culture makes it a great place to work for you to be confident it 89% I trust what my boss tells me 75% is true. But a firm need not be best-in- 75% I am able to maintain a reasonable work-life balance 50% class today to be better tomorrow. Building trust is essential. Leaders 75% 50% I like the people I work with living up to commitments and sincerely talking with employees builds trust. Making people feel a part of things and asked if they were working at full ca- or discipline issues, the supervisor giving candid feedback builds loyalty. All pacity, one-third of all respondents said perhaps should be evaluated first. of these actions must be consistent and they had more to give. You heard right: Another positive finding is that 94% sustained. Excellence isn’t a program; These people are saying they could do said they like the people they work with it’s a way of life. Creating a great culture more! They are not overworked; they and 83% said they would reapply for is an all-hands effort that starts with are underchallenged. This finding their current job. key leaders across all levels of the orga- underscores the idea that, rather than There is no single solution to im- nization working together to execute a blaming the employee for performance prove culture. Everyone should look coherent human capital strategy. CC

Wally Adamchik is the president of FireStarter Speaking and Consulting and is a recognized authority on leadership in construction. For a copy of the full report, contact him at [email protected].

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wycotool.com UNCOMMON SENSE

Craig Cottongim [email protected]

Leading Our Laborers They may be the most important and least appreciated workers on your jobsite.

AT THE TIME, I didn’t know how good I had it—some of my fondest to work with our crew to help us improve our slabs. Laser memories in our industry are from those days. For nearly a screeds didn’t exist yet, but I think the consultant’s advice ap- decade, I was in the Dupage County, Ill., laborers union. plies today: Having well-trained laborers grading the concrete But, I only saw my time there as a was the first and most important step in achieving a flat slab. Maybe the steppingstone—I had no intention of As concrete contractors, we have three reputations that we shortage of making a career out of being a “lowly la- work hard to build and maintain: with general contractors, with borer.” I was only interested in becoming our suppliers, and with our local workforce. If you are having a workers you a finisher and I grew tired of hearing the difficult time recruiting and retaining workers, which of those struggle with contractors I worked for telling me, “You three reputations do you think you might need to work on? does have a can teach a monkey how to finish, but How can we lead our laborers better? When I was a solution. good laborers are hard to find.” laborer, there wasn’t anything I wouldn’t do for Don when The reality is, regardless of whether I worked for him, and he was a hard-faced, old-school, your concrete company is union or non- tough-as-nails leader. But he treated me with respect, and union, commercial or residential, laborers are the backbone of I’ll never forget the example of his leadership. His approach: our industry. I remember one time back in the 1980s when I Cross-train your laborers among the different parts of your was a laborer for Deetch Concrete in Naperville, Ill., and there work, show them that they have an opportunity to grow was a concern over the flatness tolerances of our slabs on a within your company, and, most importantly, express your particular project. The boss, Don Deetjen, hired a consultant appreciation for their loyalty. How you communicate to your laborers truly matters. If you only communicate to command, complain, or criticize, you’ll lose out with your followers. You also have to compliment your workers (especially your laborers) on the progress they are making as tradesmen in their skills, compliment them on any job well done, and compliment them on any professional accomplishments they achieve. If you want to grow as a leader, or grow your business, ask yourself this: How much effort am I putting into the laborers who I already have on my payroll? If you can’t really think of what you are doing for the overall benefit of them, and if upon reflection you could be more proactive in developing them, maybe the shortage of workers you struggle with does have a solution. You might even be looking at that solution every ADOBE STOCK / BANNAFARSAI morning when you shave or brush your teeth. CC

Craig Cottongim is a second-generation finisher with more than 20 years of experience working in concrete. He is a writer, speaker, leadership trainer, and founder of Concrete Leadership Training.

16 November/December 2019 CONCRETE CONSTRUCTION www.concreteconstruction.net STAL IN LA GO T E IO T N S

• • S UPPORT

CONCRETE MATERIALS

TAKINGTAKING TTHEHE

OUT OF MIX DESIGN In Part 1 of this two-part series, learn the three factors that deﬁ ne a mix. BY KEN HOVER

“MIX DESIGN” IS AN INTERESTING, chal- lab- and fi eld-scale, with the expectation 1. Water content as adjusted by admix- lenging, and fundamental task. The of making adjustments based on contin- tures defi nes workability. objective is to predict the relative quanti- ued monitoring of performance. 2. Water-cementitious materials ratio ties of ingredients that will reliably and In this test-and-adjust process, ac- dictates strength and durability. economically meet the specifi cations and tual concrete performance matters more 3. Total cementitious materials is not satisfy the needs of the concrete pro- than the mix-design method because only a primary cost factor but also ducer and contractor, preferably using there are no guarantees in mix design infl uences heat, chemical reactivity, local materials. and each mixture must account for the and shrinkage tendency. A wide variety of mix-design methods characteristics and variability of local These three factors cannot be indepen- are used, varying from simple volumet- materials. Even though most concrete dently selected. At best, the mix designer ric batching (by hand) of a 1:2:3 mix is batched by weight, this article also can select any two and accept the depen- (cement:sand:coarse aggregate), to so- explores the relative volumes of paste, dency of the third, or else turn to admix- phisticated, computer-based techniques, air, and aggregate. tures and specialized aggregate grading. all of which are intended to produce But regardless of the mix-design a good-fi rst-guess called a “trial mix.” method, there are three characteristics A concrete producer can generate their own Then the trial mix has to be evaluated at of concrete that we are trying balance: unique materials database.

www.concreteconstruction.net CONCRETE CONSTRUCTION November/December 2019 19 CONCRETE MATERIALS

DON’T MISS HOW A MIX WORKS and a stress in the paste around 1,500 psi. PART 2 A good starting point is to recognize that the Add in the heat generated by the reaction of paste, consisting of water and cementitious the cementitious materials and water, and the In the January issue, materials, is the adhesive that glues the ag- tendency for paste to shrink far more than we will publish Part 2 gregates together into a strong and durable aggregates, and we realize that designing an of this article, in which hardened mass. Except in very high-strength optimal mix means finding a way to minimize Ken Hover will make mixes, the aggregates are the strong links in the paste and maximize the aggregates. You’re some suggestions on the factors that lead to the concrete chain, while the paste is softer, on the right track towards this optimal blend an increase or decrease more absorbent, more vulnerable to freeze- when you choose coarser over finer aggregates in the water demand of thaw damage and deleterious chemical reac- and pay attention to blending aggregate sizes a mix. He will then go on tions—and it is what shrinks. so as to not jeopardize workability. to describe the trade- Most high-quality natural aggregates have offs in a mix design for a stiffness (what designers call a modulus THE PASTE IS A LUBRICANT achieving the required of elasticity) four to five times greater than In fresh concrete, the cementitious paste strength and durabil- the stiffness of the hardened paste. At low lubricates the aggregate particles, making it ity while still getting a stresses, before concrete begins to crack, the easier for them to slip past each other. For placeable and workable paste and aggregate are locked together and example, compare the steepness of the sides concrete. He concludes deform equally, with a resulting level of stress of a stockpile of crushed stone with the much with a quote from his in the aggregate particles that can be four to shallower “angle of repose” observed with even mentor, cement chemist five times greater than the level of stress in the low-slump concrete. Floyd Slate, who always softer paste. As with any lubricated surface or greased said, “Remember that in For example, when we say that the com- bearing, the effectiveness of the cementitious a concrete mix, every- pression stress in a concrete cylinder is 4,000 paste in reducing the friction between the ag- thing affects everything psi, that value is an average of what may be gregate particles will depend on the viscosity of else.” a stress in the aggregates of over 10,000 psi the paste and the thickness of the paste layer. While pastes with lower water-cementitious materials ratios are generally stickier and Nominal Maximum Aggregate Size, mm more viscous, this effect can be overcome by increasing the total paste content to build 50 38 25 19 13 10 thicker paste layers between the aggregates 6 600 (this is the strategy adopted in ACI 211.1). Surface Area Per Ton The total amount of paste required in the For Speciﬁc Gravity = 2.65 mix is therefore going to be largely influenced 5 Density = 165 lb/ft3 by the total surface area of all the coarse, 33 500 C intermediate, and fine aggregates that must be M ST coated by this paste-lubricant. Figure 1 shows A r #8 Pe approximate total surface area per ton of coarse 4 g in 400 ad aggregate, ranging from about 1,500 square feet Gr e 1 Fin per ton for a #467 (1 /2-inch) stone, to more 3 3 #7 than 5,000 square feet per ton for #8 ( /8-inch) 300 stone. Maintaining a thick-enough paste layer for workability with #8 aggregate will require far #67 3 3 more paste than for a mix with #67 ( /4-inch) C3

2 #57 Agg. Surface Area Per Ton Area Per Surface Agg. TM 200 stone that has only half as much aggregate 2 r AS Pe ding surface area per ton. And since there is only 27 #467 Gra arse cubic feet in a cubic yard, and all ingredients #357 Co Agg. Surface Area Per Metric Ton Area Per Metric Surface Agg.

1 2 100 are claiming their share of that volume, any 1,000 ft

m time that paste content has to increase, aggregate content consequently has to decrease. 0 0 This can get dicey when shrinkage is criti- 1 3 1 3 2 1 /2 1 /4 /2 /8 cal since the paste leads to shrinkage while Nominal Maximum Aggregate Size (inches) aggregates resist shrinkage. This really comes home to roost where thin slabs and overlays

The total amount of paste required in a mix is largely influenced by the total must be cast with small aggregates to meet Figure 1: surface area of all the aggregates. the building code mandate that the nominal

20 November/December 2019 CONCRETE CONSTRUCTION www.concreteconstruction.net

CONCRETE MATERIALS

maximum aggregate size of the coarse aggregate not Over-sanded mixes can clog a pump as much as a mix that is exceed one-third of the slab thickness. Such small ag- 1 3 too rocky. gregates, often /2 or /8 inch, will require high water content and a high paste content, which increases the likelihood of higher shrinkage. Couple this with the fact that thin slabs and overlays can dry very rapidly because of their high surface-to-volume ratio, and the stage is set for the all-too-common shrinkage cracking in thin unbonded overlays. THE PASTE IS ALSO AN ADHESIVE But the paste, regardless of the blend of cementitious materials, is not only a lubricant for the fresh concrete but also an adhesive for the hardened concrete. In es- sence, the blended dry cementitious powders consti- tute a cost-effective, industrial-strength instant glue, activated by the mere addition of water. This reaction, which promotes strength-gain and porosity-reduction, continues only as long as drying is prevented and water is available. As with any dry instant adhesive, increasing the amount of water added to a fixed amount of powder leads to two fundamental consequences: 1. Extra water always leads to increased fluidity and lower viscosity of the liquid lubricant/adhesive. 2. Adding water to a fixed amount of powder will NOBODY HAS YET COME UP WITH always dilute the adhesive capability of the paste. A FLUIDITY ENHANCER THAT This is because water-addition pushes the powder IS MORE EFFECTIVE, CHEAPER, particles farther apart, making it more difficult to OR MORE READILY AVAILABLE THAN establish the critical bonds from one particle to the next that give concrete its strength. Water addition WATER, BUT THAT DOES NOT HAVE also creates larger gaps between the particles that THE STRENGTH-REDUCING allow the passage of gases, liquids, and contami- POWER OF WATER. nants through the hardened concrete. These simple observations bring us to the fundamental quality-control challenge in the concrete industry: water-addition increases fluidity and workability, and at the same time decreases strength and durability of the hardened product, without exception. The fundamental trade-off in our industry has always been balancing the owner’s needs for strength and durability with the producer’s and contractor’s needs for concrete that can be placed, consolidated, and finished. While admixtures and improved aggregate grading can go a long way toward making this balancing act possible, nobody has yet come up with a fluidity-enhancer that is more effective, cheaper, or more readily available than water, but that does not have the strength-reducing power of water. Water content is critical for workability because it influences both the lubricating ability of the paste and the thickness of the paste-layer coating the aggregate particles. This relationship can be seen in Figure 2

Water content for various aggregate sizes, based on showing where the aggregate-size effect comes into play. Figure 2: ACI 211.1 for non-air entrained concrete. The graph demonstrates the basic water requirement

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prior to adjusting for combined aggregate grading, air entrainment, or other admixtures. For a desired 5-inch slump, the water content varies from about 310 pounds 1 of water per cubic yard for 1 /2-inch stone, to about 350

pounds per yard for 3/4-inch stone, to 400 pounds of

water per cubic yard for 3/8-inch stone. At any preselected ratio of water to cementitious materials (w/cm), more water is simply going to mean greater paste volume, and greater paste volume will generally lead to increased shrinkage—as shown in Figure 3. WHAT’S ALL THIS ABOUT w/cm ? The ratio of the weight of water to the weight of dry cementitious materials (water-cementitious materials ratio, w/cm) is a key index of the strength and durability of the paste that acts as the adhesive holding the aggregate together to form the concrete. This is best Greater paste volume, and higher water-cement ratios explained in Figure 4, showing our human-eye-view of Figure 3: leads to increased shrinkage (adapted from Nawy). ordinary concrete on the left, then magnified 100,000 times on the right. In the picture on the right, you’ll see the strength and mechanical properties develop from the particle- to-particle bonding of the crystal-like products protruding from the hydrated grains of cement powder, while the dark void spaces in between are the passage- ways for transport of water, oxygen, carbon dioxide, sulfates, alkalis, and chlorides. These void spaces have their origin in the volume occupied by the water in the fresh concrete. The lower the amount of water in the fresh paste relative to the amount of cementitious materials, the less void space and the lower the permeability of the hardened concrete. Likewise, the lower the w/cm, the higher the com- Concrete may look solid (left) but at high magnification pressive strength, tensile strength, and modulus of Figure 4:(right) its porous nature is revealed. elasticity. In addition to the fundamental influence of w/cm, mechanical- and durability-related properties are also influenced by overall mixture proportions and the selection of other ingredients, making it difficult to predict strength or durability on the basis of w/cm alone. Nevertheless, ACI 211.1, Standard Practice for Select- ing Proportions for Normal, Heavyweight, and Mass Con- crete, cites the relationship between w/cm and 28-day compressive strength for non-air-entrained concrete, as shown in Figure 5. The 236-psi-per-gallon line is approximately the ACI 211.1 relationship between w/cm and compressive strength. The other lines are from a series of concrete mixes produced in a ready-mix truck. In general, nearly all mixtures achieved a somewhat higher strength than predicted at any value of w/cm. This is not too surpris- ing since the ACI data is old and modern cements are more efficient.

Compressive strength is reduced by increased water While there are obvious differences among the per- Figure 5:content, although mixes vary with constituents. formance of the various mixtures, the data verifies the

24 November/December 2019 CONCRETE CONSTRUCTION www.concreteconstruction.net

CONCRETE MATERIALS

shape of the ACI strength relationship strength reduction due to an increase in database as a more reliable predictor and demonstrate the fundamental prin- water content ranged from 148 to 236 than nationally published data. ciple that increasing water content for psi per gallon, as influenced by other The w/cm also has an impact on the a fixed weight of cementitious material mixture characteristics. Any concrete permeability of hardened concrete (the decreases the compressive strength. For producer can keep track of w/cm and rate at which pressurized liquid water the three mixes shown in Figure 5, the generate their own, unique materials can be forced through hardened concrete). The trend with any mix is rapidly escalating permeability with increasing w/cm, which leads to rapidly declining service life. PUTTING IT ALL TOGETHER A typical concrete mixture is likely to have a total air-free paste volume in the range of 25% at the low-shrinkage end up to somewhere around 30%. If we add 2% to 8% air to cover the range from non-air-entrained to air-entrained concrete, the combined water, cementitious materials, and air bubbles can represent STRONG FOUNDATIONS START 27% to 38% of the volume of the concrete. The rest is the combined aggregate volume in the range of 62% to 73%. WITH OUR CUSTOMER Jim and Jay Shilstone always advo- cated further defining the “mortar volume fraction” as the percent of the concrete volume that includes everything except the coarse aggregate. Although the guide- SERVICE lines get complicated, a mortar volume fraction of 50% is about right for most mixes using clean, rounded gravels, and closer to 60% for crushed stone mixes. Zimmerman Industries, Inc. leads the mobile concrete This is because the mortar separates the industry with over 50 years of experience, and our aggregate particles and rougher textures customer service shows it. require more separation to achieve workability, pumpability, and finishability. What can Zimmerman Industries offer you? But when mortar fractions get much higher than these general numbers, it • Excellent service from the original mobile concrete inventor can often be an indicator that the mix is • Patented independent chain feed delivery system with a 3-year “over-sanded,” leading to a mushy con- or 12,000-yard warranty sistency that can clog the pump as much • Lowest annual maintenance cost of any volumetric mixer available as a mix that is too rocky, and cause finishing problems besides.CC • On-location operator training

Get the full experience at zimmermanindustries.com.

Ken Hover is professor of civil and environmental engineering and the Stephen Weiss Presidential Fellow at Ephrata, PA USA • 717-733-6166 zimmermanindustries.com Cornell University, in Ithaca, N.Y. He [email protected] is a former president of the American Concrete Institute and a popular World of Concrete speaker.

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This seminar covers the best practices for the shotcrete contractor looking to grow and increase production and quality in their shotcrete applications. This is a valuable course to learn more about the details and requirements for quality shotcrete placement and a powerful companion to the shotcrete nozzleman education. www.shotcrete.org/WOC | [email protected] Launched in 1956, CONCRETE CONSTRUCTION’s track record of 60+ years is built around principles of authentic industry engagement, active participation and promotion of concrete innovation, education and building methods.

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Material Placement Made Easy

Fill and subgrade materials can be air-pumped into inaccessible locations.

BY BILL PALMER || CONCRETE PUMPS TODAY are How It Works a lightweight, non-marking hose at the the primary way to place concrete. But The patented, self-contained system point of placement. When customers are what if the material you need to place includes a two-axle fl atbed truck with using the pump, there’s an operator at is dry sand or gravel? Contractors have compressor, hydraulically operated the pump and a laborer at the end of struggled for years to move sand, soils, pump, and hose reel. Mobilization is the hose. Each has a radio so they are and aggregate into inaccessible locations simple, and because there are no outrig- in constant communication, can stop where earth-moving equipment won’t fi t gers or other external requirements, the or start the pump, or vary the amount or other constraints won’t allow for it. unit can operate in a single lane without of material discharging. “We’ve also had Increases in labor costs and risk of bodily disrupting adjacent traffi c. sensitive areas where customers don’t injury have made the old wheelbarrow The material to be moved is typically want bulk material on the ground,” No- or bucket method of moving materials a dumped at a jobsite in bulk. It is then len says. “In this case, we order the dry thing of the past. loaded into the Air Pump hopper with material to be delivered directly to our The Air Pump was developed in 1996 a skid steer where it runs through the air-pump hopper by way of drum mixers to tackle these challenges. This equip- pump and is discharged from the end of or slinger trucks.” ment uses compressed air to deliver a variety of materials—sand, stone, crushed rock, decomposed granite, rock dust, and landscape soils—to distances upwards of 600 feet away. In addition to its original design application of backfi lling concrete foundation walls, the system is used to fi ll abandoned wells, pipes, and culverts; planter boxes on elevated structures with both drainage rock and landscape soils; annular spaces for drilling and boring contractors; beach replenishment projects; and nondestructive placement of topping materials on turf systems. “The operation is very similar to a concrete pump; however, the technology of moving dry materials is very different,” says Michael Nolen, president of Air Pump USA, in Gardena, Calif., which manufactures the unique equipment and also operates as a subcontractor. “We work as an ally to the local concrete pumping contractors, solving customers’ access challenges with the most effi cient piece of equipment.”

1 The hose for the air-pumped material is easy to control. 1

www.concreteconstruction.net CONCRETE CONSTRUCTION November/December 2019 29 INNOVATION

2 A skid steer is used to load the pump hopper.

3 Dry material can be pumped up to 10 stories vertically and 300 feet horizontally.

4 A slab subbase can be placed easily indoors with the Air Pump. 2 3

Each Air Pump truck is equipped dust suppressant. “The benefi ts of adding continue working while the backfi lling with two hydraulically powered pumps proper moisture content at the discharge operation is in progress. And the process that allow for simultaneous placement end is twofold. It aids in suppressing dust is worker-friendly since the line pressure at two locations, increasing productiv- and can also help achieve proper compac- is only about 150 psi (compared to much ity and allowing crews to complete their tion when needed,” Nolen says. higher pressures in a concrete pump). work in a shorter time. “When pump- When the job is complete, the 50-foot Unlike water hoses or concrete hoses, the ing material, the hose weighs about 2 hose sections are either taken apart and air-pumped sand, gravel, and soil system pounds per foot, which is much lighter brought back to the truck or the hydrau- has very little back pressure, which and easier to maneuver than a hose lically driven reel assists in bringing the means workers never have to wrestle to completely full of concrete. At the end hose back on board. keep the hoses under control. “It can pull of an installation, or at a break, we are The newest units are capable of back if you pinch it at a corner, but noth- able to stop adding material and keep pumping sands and aggregates up to 35 ing like a shotcrete or concrete hose,” the pump going until the hose is totally tons per hour and soils up to 40 cubic Nolen says. The lightweight hose and the blown out and clear,” Nolen explains. yards per hour over distances of 600 feet, even fl ow of material allows a smaller In some sensitive applications, workers depending on specifi c site conditions such crew to place and grade more material will use a diffuser on the end of the hose as material type, distance, and elevation than with other methods. coupled with a water stream to act as a change. On a recent podium apartment Once the hoses are set up and pump- project in Los Angeles, Air Pump USA ing has started, the material deliveries successfully pumped 10 stories vertically to the hopper area can be scheduled at and 300 feet horizontally. The customer constant intervals allowing for minimal had originally budgeted the placement traffi c and jobsite disruptions. using cranes, buckets, and wheelbarrows. Thinking outside the box and using the Applications Air Pump equipment saved the contractor New locations and numerous uses for over $100,000 in labor costs and months the Air Pump equipment are called for of valuable job schedule time. each week. Many of the large national The Air Pump unit can be parked well landscaping fi rms such as Brightview, away from where the material is needed, Park West, and Landscape Development making the whole process very discreet. Inc. are depending on the equipment 4 On construction sites, other trades can regularly to service their diffi cult projects

30 November/December 2019 CONCRETE CONSTRUCTION www.concreteconstruction.net

Air Pump USA has recently been used update its patents. It has begun to to replenish the beachfront at coastal expand its geographical reach through properties in California from San Diego new partners and improvements up to Santa Barbara. “We are constantly to its designs. They currently oper- having new applications arise,” says No- ate fi ve units in Southern California len. Many city building specifi cations are and recently partnered with material requiring new mechanical and electric placement businesses in Michigan line conduit to be encased with “air- and Colorado. blown sand” under roadways. Many of “We design and operate our own the new uses are by landscape contrac- trucks,” Nolen says. “We’ve manufac- tors who are completing the mandated tured and sold trucks to a select few 5 green spaces and green roofs on podium outside operators who fi t our criteria In sensitive areas, dry material can be offi ce and apartment buildings that are and provide top-notch service in their 5 loaded into the Air Pump from a mixer truck. infi lling our urban cities. respective markets. We will continue op- quickly, safely, and productively. Con- “It never gets old hearing customers erating as a hybrid, growing our service crete contractors Webcor, McCarthy, and thank us for how easy, effi cient, and safe business, developing new, more-effi cient Largo have used the equipment to place the system worked in completing their prototypes, and selectively selling to wall backfi ll and subgrade sands be- task,” Nolen says. “ ‘I wish I would have customers that we think can be success- neath slabs on grade. Boring contractors known about this equipment years ago,’ ful with the equipment. The challenges have used the equipment for annular is another line I often hear.” that customers continue to bring us spaces, fi lling the void between conduit keep us pushing the envelope in design and lines; interlocking paving install- Manufacturer or Service Provider? and possibilities. We have assembled a ers for setting bed sand; and plumbing Air Pump USA continues to test the great team and are really excited about contractors for trench backfi lls. boundaries of its equipment and the future of Air Pump USA.” CC

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32 November/December 2019 CONCRETE CONSTRUCTION www.concreteconstruction.net NEWS THAT’S CONCRETE

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Insulating Concrete Balconies

Structural thermal breaks are increasingly used to save energy and eliminate cold ﬂ oors, condensation, and mold growth.

BY DRITAN TOPUZI

THERMAL BRIDGING OCCURS when building The structural thermal break is elements (such as balconies, slab edges, tied into position with wire ties. CREDIT: SCHÖCK NORTH AMERICA or parapets) of a high thermal conductivity material (such as concrete or steel) protrude through the building’s exterior insulating layer, allowing heat energy to be rapidly conducted from the building interior to the exterior. Architects and engineers have employed strategies such as improved insulation, triple-glazed windows, air-to-air heat exchangers, and airtight building envelopes to improve building energy performance, but protruding structural elements like concrete balconies provide a highly conductive thermal bridge for interior heat to dissi- pate into cold exterior environments. Left unaddressed, concrete balconies chill interior slabs, causing interior surface temperatures near the balcony penetration to fall below the dew point, resulting in condensation, mold forma- tion, and deterioration of materials. Concrete balcony degradation has been a huge problem in high-rise residential towers around the world. The rate of heat transfer depends primarily on the temperature difference across the thermal bridge, the thermal conductivity of the protruding materials, and the cross- sectional area of the thermal bridge.

Addressing Thermal Bridges Few North American building codes and energy standards currently address exactly how thermal bridging should be mitigated, but that is changing. Studies have been conducted and code com- mittees are looking at altering building

www.concreteconstruction.net CONCRETE CONSTRUCTION November/December 2019 35 Installing a Thermal Break BY BILL PALMER

AT ITS SIMPLEST, a structural thermal break is a reinforced construction joint fi lled with insulation. The reinforcing steel on the interior runs to the edge of the slab. The thermal break, with 30-inch stainless steel reinforcing bars protruding from the top on each side, is positioned at the edge of the slab and wire-tied to the interior steel. The rebar on the top of the thermal break acts as a tension member to support the cantilevered balcony slab. Likewise on the exterior balcony slab, the stainless is wire-tied to the rebar, which is sometimes epoxy-coated. The balcony formwork is shored during concrete placement. “In applications with a mild steel-reinforced slab it’s fairly simple,” says Nate Lambrecht, regional sales and engineering manager for Schöck North America. “You are basically creating a slab edge condition with a 7-inch gap between the slab and the balcony. Our materials just drop into that gap where it effectively acts as an in-place pour stop.” On the bottom of the thermal break assembly are high-strength compression modules that bear against the Balconies are sometimes interior and balcony slabs and that are fi lled with 17,500 psi reinforced with epoxy-coated compressive strength concrete. This means the insulation rebar. CREDIT: SCHÖCK NORTH AMERICA is not bearing any signifi cant load. To support the compression load on the bottom of the thermal break, additional reinforcement is positioned in the slab edge. “Since the top codes to specifi cally address almost impossible to achieve bars are in tension, the compression modules at the bottom thermal bridging at balconies prescriptive compliance with- of the connection are engaged by the adjacent slab edges,” and other protruding struc- out the use of some sort of slab says Lambrecht. “Because of that, additional attention is tural elements. Developers are edge thermal break. Balcony required beyond a typical slab edge. Additional longitudinal also independently looking at thermal breaks improve the bars and either downturned bars or U-bars are required to improving their construction overall R-value signifi cantly.” stiffen it up so it doesn’t spall when the compression modules engage. If we have small balconies not much additional practices to increase the value The RDH study examined edge reinforcement is required but if you have large cantile- of their investments. four different ways to reduce vers, we’re going to ensure that that edge is stiff enough to A study on thermal bridging concrete-balcony-induced support the assembly at the bottom of the slab.” at balconies was conducted thermal bridging, including The thermal break can also be used with post-tensioned by RDH Building Science: decks. “With PT, accommodating a dead end is very “The Importance of Slab Edge Structural thermal breaks installed simple,” says Lambrecht, “you just place it behind the ther- & Balcony Thermal Bridges” along the junction of the inner curtain mal break allowing enough room for concrete consolidation; wall and building core at Pittsburgh’s where you have to have access to a live end, you simply (Sept. 24, 2013). The study’s Tower at PNC Plaza provide both leave a void between the structural modules and create a conclusion: “When slab edges structural support and insulation to minimize heat transfer through block out to access the tendon at the line of the interior slab or balconies are incorporated thermal bridges penetrating the edge. Then the contractor will tension, secure, and trim the in a building design, it can be building envelope. CREDIT: GENSLER tendon, and place an insulation block between the structural modules, maintaining thermal break continuity.” Thermal break modules come in standard lengths but can be cut easily with a hand saw as needed to match the balcony contour. Similarly structural thermal breaks are produced in standard incremental heights up to 10 inches in depth. “If the slab depth exceeds a standard height, most often the contractor can simply add insulation material,” says Lambrecht. “As a manufacturer we look to optimize designs using full length modules and standard heights whenever possible. If there are areas where you need another 6 inches or even a foot, we will use our insulation module which is effectively the body of the thermal break without the bars and compression modules to maintain fi re continuity. From the design side, an architect or engineer simply needs to indi- cate a thermal break line and we will defi ne what materials to use where and the spacing and issue the shop drawings.”

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an effective thermal separa- ported by a cantilevered Cantilevered balconies separated from the building tion in the slab by replacing balcony structure on 30 slab by a thermal break are the solid reinforced concrete fl oors. To prevent thermal supported until the concrete has reached the specifi ed strength. at the connection with an bridging, the design team CREDIT: SCHÖCK NORTH AMERICA optimized structural system of Gensler, BuroHappold consisting of: Engineering, and Heintges • Insulating material such Consulting Architects & En- as expanded polystyrene, gineers installed 1 mile of the which is non-structural Schöck Isokorb concrete-to- and constitutes the main concrete structural thermal body and surface area of breaks between the inner the thermal break. wall and the building core. • Reinforcing steel bars, Hao Ko, managing director which go through the in- of Gensler’s San Francisco sulation body of the ther- offi ce, quipped, “Without the mal break and are made thermal breaks it would be of stainless steel, which is like wearing a down jacket, only 30% as conductive as but leaving it unzipped.” carbon steel. Additionally, their corrosion resistance Complying With Building improves the durability of Codes and Providing the cold joint. Tangible Value • Concrete modules, which Though primarily used to are made of ultra-high increase the building’s value performance concrete by preventing condensation, reinforced with steel fi bers mold growth, and heat loss, in order to minimize the structural thermal breaks amount of conductive con- are also enabling develop- crete material for higher ers to meet evolving building thermal performance. code requirements through- This assembly of steel and out North America. Struc- concrete provides the neces- tural thermal breaks have sary shear and fl exural become an effi cient and eco- strength at the connection. nomical solution for developers looking to improve build- Preventing Heat Loss ing envelope performance, and Mold and comply with increasingly manufactured purpose- slab-edge thermal break The 33-story, LEED Platinum stringent building codes. CC built concrete slab thermal systems provide architectural Tower at PNC Plaza in Pitts- breaks. It concluded that freedom to designers while burgh features a double-skin Dritan Topuzi, PH.D., “the modeling demonstrated maintaining the building’s façade with an interior and P.ENG., PMP, LEED AP, is that the thermal- and cost- thermal performance char- exterior glass curtain wall as product manager for effectiveness of structural acteristics to reduce building a primary element in its ener- Schšck North America. slab cut-outs, concentrated energyenergy consumption,consumption, improveimprove gy-savinggy-saving strategy.strategy. BetweenBetween slab reinforcement, and full thermalthermal comfort,comfort, andand meetmeet thethe curtaincurtain wallswalls isis a balcony insulation wraps is increasinglyincreasingly stringentstringent build-build- walkingwalking surfacesurface relatively poor compared to inging codecode requirements.”requirements.” sup-sup- manufactured slab thermal OtherOther researchresearch conductedconducted breaks and therefore were byby SchöckSchöck concludedconcluded thatthat not pursued further within structuralstructural thermalthermal the study. Overall, balcony breaksbreaks provideprovide

Schöck Isokorb structural thermal breaks for concrete construction contain insulation and load-bearing components with rebar that is fully cast into interior and exterior concrete structures at the penetration.

38 November/December 2019 CCONCRETEONCRETE CCONSTRUCTIONONSTRUCTION wwww.concreteconstruction.netww.concreteconstruction.net Featured Products: Lavina Air Scrubber, Lavina 32RE Grinder (remote-controlled), Lavina V32-X vacuum.

complete solutions for floor grinding, polishing and maintenance

Superabrasive manufactures a wide range of tooling options for every job from prep and removal to daily maintenance. We have added a variety of hybrids and resins to our Quick Change tooling portfolio, so you can work more effi ciently.

Visit www.superabrasive.com to learn more.

Interlocking yellow ribbons welcome military journalists to the Defense www.concretesurfacesmag.com Information School.

TIE A YELLOW RIBBON Sometimes the only way to ﬁ x a bad polishing job is to start over.

BY BILL PALMER

www.concretesurfacesmag.com CONCRETE SURFACES November/December 2019 CS-41 SHOWCASE

Reviving this floor meant starting with a cut back to the coarse aggregate.

Workers hand cut the demising lines on the ribbon edges and used a Dremel to extend the cut to the wall.

POLISHING CONTRACTOR: PROJECT: THE DEFENSE INFORMATION SCHOOL Industrial Caulk and Seal, Defense Information Delta, Pa. (DINFOS) at Fort Meade, Md., serves as the School, Fort Meade, Md. United States’ only educational facility for train- GENERAL CONTRACTOR: PROJECT SIZE: ing military journalists to document and com- Frederick Concrete, 4,000 square feet municate the activities of the country’s military Frederick, Md. around the world. As such, the main entrance hallway to DINFOS welcomes students from across all military services who are going out A single dye on assignment as well as those who are com- color was used ing back. The yellow ribbon they see there on for the ribbons, the floor is in honor of the men and women using multiple deployed in service to our country. applications Unfortunately, that floor and ribbon did not to get measure up to its mission. “This was origi- complementary nally a polished floor that had been poorly colors. executed and there was significant cracking in the slab from the original construction,” says Chip Marshall, executive vice president at Industrial Caulk and Seal (ICS), in Delta, Pa. Even though only two years old, the polished floor didn’t shine and the yellow ribbon blurred into the surrounding concrete. DINFOS leadership was very disappointed. “A polish is not always a polish,” Marshall says. “This floor had a milky appearance. It had been heavily guarded and the shine was gone.” ICS was brought in by the original concrete contractor to make it right. After some tests to determine what was possible, they decided the only reasonable approach was to grind the floor clear back to the coarse aggregate

All photos: using 40-grit metal grinding pads and go Industrial Caulk and Seal through the entire polishing process again.

CS-42 November/December 2019 CONCRETE SURFACES www.concretesurfacesmag.com After the initial grinding steps, workers of the largest polishing contractors in rely on a set prescriptive process for placed demising cuts to define the edges the eastern U.S., working from South every floor. “We do extensive training to of the ribbons. “We had cut all of the Carolina to Maine to Ohio. But as they get our foremen to push their creative color off the floor,” Marshall explains, “but grew, the company spent resources to level,” he says. “We count on our guys to you could still see some shading from the maintain a high level of craftsmanship be craftsmen in the field more than most original lines. So we had a cheat sheet as among its workers and not have them large polishing contractors.” far as layout of the ribbons, and we just had to connect the dots. We didn’t use any sort of center pivot for the grinders; we count on our guys to be craftsmen. Every line was hand cut with an angle grinder. To extend cuts tight in to the wall, we use a Dremel—and still it’s all freehand work.” ICS took the floor through an eight- step polishing process: 40 and 80 met- als, then to 50 hybrids, 100, 200, 400, 800, and finished at 1,500. This provided the clarity and quality DINFOS was looking for. The ribbon color was applied concrete using what Marshall calls a “sandwich process.” “We use an initial application of densifier at 100 and then dye at 400 but dimensions then we redensify after the dye—that’s what we call ‘the sandwich process.’ REUSABLE We feel this locks the dye into the floor, URETHANE especially in areas with heavy traffic. This technique was perfected by Chris Kilgore, STENCILS our operations supervisor, who was also Introducing Brickform’s the foreman on the DINFOS project.” latest innovation for decorative concrete! To get the two complementary ribbon Our Concrete Dimensions hues, ICS did not use two different dyes reusable urethane stencils but simply did multiple applications of leave behind crisp, clean - Ameripolish Gold to get the darker hue. designs providing an alternative way to create On the background, they used an Ameri- shape and form in polish dark gray dye to contrast with the concrete surfaces. gold ribbons. Then there was the issue Float Concrete Dimensions of what to do with 190 feet of cracks and stencils into freshly placed unfilled joints. “We filled the joints and concrete, then trowel cracks using three caulks to color match smooth, broom finish, both the stripes and the surrounding apply texture or expose the concrete aggregate. concrete,” Marshall says. The durable, flexible ICS came early to the polished con- urethane allows the stencil crete floors business, in about 2002, to be removed from starting as a caulking company that was hardened concrete, rolled up, and reused time and awarded a contract by Ikea for a pol- time again. ished floor. “We got into it kind of by ac- cident and thought polishing would be a supplement to our sealer work,” Marshall (800) 629-0261 says. “So we bought a small company www.brickform.com that had two guys experienced in polish- www.solomoncolors.com ing and had two machines, a Draygon and an HTC 500, one of the first ever produced that is actually still in use.” Today, ICS has grown to become one www.concretesurfacesmag.com More concrete forming value, supplied by dealers nationwide!

• Bar Chairs • Coil Rod • Coil Ties • Floor Dowels • Form Ties • Metal Rib • Pipe Braces • Post Shores • Precast • Slab Bolster • Staybox • Stud Rail • Shoring • SurePly Forms • Taper Ties • Tilt-Up • Walers

Leverage branded content from Concrete Construction to create a more powerful and sophisticated statement about your product, service, or company in your next marketing campaign. Contact Wright’s Media to find out more about how we can customize your acknowledgements and recognitions to enhance your marketing strategies.

Call Wright’s Media at 877.652.5295, visit our website at wrightsmedia.com/sites/hanleywood or email us at [email protected] POLISHED CONCRETE

Getting Consistent Results on Polished Concrete Overlays Follow these three steps for a successful installation.

By Joe Zingale

POLISHABLE CONCRETE TOPPINGS one person in charge of both the water tion. Mix in larger batches (four to five are a popular choice for both damaged and mix station on a jobsite will help. This bags) to ensure consistency. Working floors and new construction. For existing person should also perform slump tests with larger batches combined with con- 3 floors, in particular, /8-inch bonded-con- and be responsible for hitting the desired trolling the width of the pour allows you crete overlays provide a versatile decora- target. Slump tests are especially impor- to keep a proper wet edge. Wet material tive option. Project owners can choose tant when colorants are being added. needs to be placed into wet material to from a variety of colors and aggregates At Total Surface Solution, in Maple- avoid cold joints. Then a gauge rake is to create unique, multicolored designs, wood, N.J., the team begins a project by used perpendicular to the direction in produce a terrazzo look, or match slabs experimenting with the water ratio until they which the material was placed. Nowa- to adjacent flooring. have the slump they need. “You must be days, a spike roller is typically used in Contractors often face challenges, diligent with your water ratios,” says Todd the same direction that the material was though, when asked to produce a Sherman, founder and CEO. “Once you first placed in order to release trapped air uniform appearance in a polished have determined the water ratio, you must and create an ideal surface for grinding concrete overlay. To achieve consistency be consistent throughout the project.” and polishing. in each project, ensure the necessary Bottom line: Use proper mix Take, for example, a project for which steps are being taken before grinding proportions to keep aggregate suspended a contractor would use two large mix- 3 and polishing begins. and near the top of the surface, and be ers for a /8-inch placement. Those two mindful of how much water you’re using. mixers can process 80 to 100 bags per 1. Control the Water in the Mix hour, which is enough material for about The mix can make or break a project. A 2. Limit the Size of Your Work Area 1,200 to 1,600 square feet of floor. For polished concrete surface should show Why pour a 40-foot-wide area when you that production rate, figure out the best aggregate consistently. If there’s too can pour a 20-foot-wide area and get pour width or use additional mixers if much water in the mix, the aggregate will more consistent results? It makes better the project requires a wider pour. sink and won’t be visible when grinding, sense to align the width of the pour to Bottom line: Mix and place what resulting in an inconsistent floor. Having the production capacity of the mix sta- your mix station can actually produce.

Keep the same worker at each mixing station to maintain consistency. Maintain a wet edge when placing an overlay.

www.concretesurfacesmag.com CONCRETE SURFACES November/December 2019 CS-45 POLISHED CONCRETE

Installing a healthy polished concrete overlay is all about adhering to the recipe. Don’t let too much water ruin the mix and don’t place material in wider strips than your mix station can produce.

CONCRETE PREP PLUSª THE REVOLUTIONARY DIAMABRUSH™ BY MALISH

3. Monitor Air Temperature/ Movement Elevated temperatures will reduce your working time. When working in temperatures above 70 F, contractors may THE ULTIMATE need to shorten the width of the pour to CONCRETE PREP TOOL keep a wet edge. When pouring indoors, SAVE TIME & INCREASE EFFICIENCY climate-controlled buildings can keep ■■Designed for concrete floors with hard-to- temperatures consistent. The concern remove and/or multiple layers of coatings then becomes eliminating air movement. ■■ Self-leveling concrete dries from the top REPLACEABLE BLADES Lasts up to 3 to 4 times longer than our Standard Prep Tool down, so it’s essential to ensure fans Easily change used or worn are not blowing to avoid cracking due to blades, minimizing downtime ■■Super durable cutting blades prep floor premature drying. in a fraction of the time During pouring and curing, it’s impor- ■■ Attaches to your existing floor maintenance tant to adhere to the instructions for the equipment cement. “We use CTS Rapid Set products ■■Flexible blades remain in contact with the and they provide detailed specifications for floor regardless of floor imperfections their products, which helps the process,” Sherman says. Bottom line: Compensate for warmer temperatures and block air movement for better results.

800.321.7044 The Polishing Crew Will Know During the first step of the grinding WWW.MALISH.COM See us at Booth #O40627 stage, a polishing contractor can tell if the mixing and placement was done

www.concretesurfacesmag.com At this Under Armour store in Wisconsin, a thin polished overlay created a clean modern look.

correctly. If the aggregate isn’t uniformly distributed in the overlay material, the St T polishing contractor may have to do op R b Y y 3 B multiple passes with the initial grinding ou 0 L r b A steps to make it look uniform. Using oo % *F th S e a T the right material is important—and br t -O S ua th O F O r e W F watch the water ratios. U y 4 o F BBLALAST--OFFOFF S T -7 rld F * “Consistency in our mixes throughout 1 H , 2 o 1 H 0 f C * M 6 H 20 o our projects is very important to us,” us 2 A nc t be 6 L re to e p L t o pre e Sherman says. “Recently, on a large job, rd es er en we had to use different lots but the mix . t was still consistent from batch to batch. Effective Without Causing My team fi nds it’s easy to achieve consistent results with the Rapid Set TRU Damage to Equipment! www.nox-crete.com fl ooring products—there’s no guesswork involved to ensure the mix is correct.” BEFORE DURING AFTER Installing a healthy polished concrete overlay is all about adhering to the recipe. Don’t let too much water ruin the mix and don’t place material in wider strips than your mix station can produce. Contractors who pay attention to these details will achieve the fi nishes that their customers demand.

Joe Zingale is the ﬂ ooring group specialist • Curb Machines • Slip Form Machines • Pumps • Screeds • Saws • Mixers for CTS Cement Manufacturing Corp., • Hand Tools • Paving Machines • Hoppers & Buckets • Scaffolding in Garden Grove, Calif.

402-341-2080 | [email protected] www.concretesurfacesmag.com 2020 OUTLOOK IDEA BANK

2020 OUTLOOK IDEA BANK

World of Concrete 2020 is expecting to draw more than 50,000 attendees and showcase more than 1200 exhibits. WOC is the largest annual construction trade show in the US, bringing buyers and sellers together…As the official media partner of WOC, concrete construction is proud to introduce the 2020 Exhibitor Booth Idea bank showcasing many of the leading suppliers of the industry and the products and services they will have on display during the show…providing a unique information source for you as you begin to develop your list of must see exhibits. Vapor Barrier Safe Improves Pour Efficiency Better Overall F Numbers VAPOR BARRIER SAFE! L

INTRODUCING...

ACI Certiﬁ cation Verify App

The ACI Certifi cation Verify app allows users to quickly and easily verify the status of ACI-certifi ed individuals through three search options: (1) verify an individual’s certifi cation ID number, (2) search by an individual’s name, and (3) fi nd the total number of ACI-certifi ed individuals in an area.

Accessible through a phone or tablet, the app is the perfect tool to use on the jobsite to verify the status of people working on a project. Using the same functionality of the popular concrete.org/verify web- based verifi cation tool, the ACI Certifi cation Verify app helps the entire verifi cation process become more seamless so jobs can keep moving forward. Stop by the ACI booth #C4203 during WOC 2020 to demo the app or speak to an ACI Certifi cation representative.

The app is currently available in iOS platforms. An Android version is expected to be available soon.

ACI has certifi ed more than 400,000 concrete fi nishers, technicians, supervisors, inspectors, managers, and more since the 1980s. Currently, there are more than 123,000 active ACI certifi cations across 25+ popular programs whyACIcertifi cation.org. worldwide. 248-848-3790 2020 OUTLOOK IDEA BANK

Zim-Mixer® Volumetric Lignomat Meters to Concrete Mixer Measure Moisture in Bring New Life to Your Concrete ® The Zim-Mixer brand features the Concrete Flooring patented dual chain system, providing Lignomat features a series of moisture low maintenance costs and the ability Get the most from your concrete flooring meters with additional options for to run material independently. Units can with the Diamabrush™️by Malish Concrete the concrete contractor, allowing for be truck, trailer, skid or rail mounted and Polishing System. Utilizing progressively measuring all important parameters in a custom designed to meet your needs. finer Grit Polymer Tools in successive building: Concrete moisture with in-situ Serving the concrete industry for more steps, the system brings vibrant shine to RH measurements, ambient air humidity than 50 years, with innovation, world- even the dingiest floors and can be used and air temperature, measurements of wide leadership, quality equipment and with any standard auto scrubber. Malish moisture in building materials other than superior customer service. also offers a lithium densifier to enhance concrete. Stop by our booth # S12753, WOC Booth #N826 the shine even more. and look at all meters to measure www.zimmermanindustries.com moisture and humidity. , rh-in-situ probes 888 576 6499 Stop by Booth #040627 or visit and pin and pinless moisture meters www.malish.com to learn how Diamabrush™️ by Malish can help www.lignomat.com achieve and maintain a shine 800-227-2105 you’ll love.

This Puller/Placer Can’t Be Beat!

In January of 2019, Somero acquired Line Dragon and the synergies from this acquisition have resulted in the industry’s most advanced Puller and Placer machine.

Introducing the next generation, the Somero® Line Dragon® Line-Pulling and Placing System.

Besides being the most nimble concrete placing machine on the market, this concrete hose pulling machine is sure to enhance productivity, create labor savings, and reduce the risk of injury associated with moving concrete pump hoses by hand.

New Features & Benefits for the Somero® Line Dragon® • Improved Antenna Guard • Toolbox, for remote storage • Quick access to the hydraulic manifold • Horn featured helps to eliminate hose pinching • Protective cover for the hydraulic tank and gauges • Improved clamp and seal to reduce wear on the elbow connector. Visit us at the World of Concrete— Booth C-5303—and see this latest innovation from Somero for yourself. Pavement Panel Replacement

Maximize Productivity with 1 Hour Concrete

Rapid Set® is an ideal solution for repair and restoration of full-depth concrete pavement. On many highways, bridges, and airports, construction closures are limited to nights and weekends. Often times the crews only have 6 to 10 hours for pavement removal and replacement. Since Rapid Set concrete is ready for traffic in as little as 1 hour after placement, crews save a great deal of time during tight schedules and disruption to commuters is minimized.

Rapid Set maximizes productivity and can be tailored to your specific needs. These panel replacements have proven to be extremely durable, even in the harshest freeze thaw environments that can shorten the life of pavement. Over 1.2 million cubic yards of Rapid Set concrete pavement have been placed since 1980.

Contact CTS Cement Manufacturing Corporation 800-929-3030 CTScement.com World of Concrete Booth #S1040

Build Faster, Build Better, Build Stonger— Build with Form-A-Drain Solutions

Booth Number: N 3162 2020 OUTLOOK IDEA BANK

Floor Dowel and Joint Systems C555 Concrete Moisture Meter GelMaxx offers organic slurry solutions that allow contractors to easily Steel plates move inside plastic sleeves dispose of slurry and waste water. Our to control expansion and contraction, The C555 Concrete Moisture Meter eco-friendly products are EPA compliant provide load transfer, and improve gives you a speedy indication of high and easy to use. ECO-QUICKgel allows joint stability, in a single-cost-effective and low moisture zones, showing you users to solidify slurry and throw it away assembly. A properly installed Dowel optimal areas to place your ASTM in a standard trash can, and AQUAmaxx Basket assembly minimizes joint F2170 test probes within the concrete separates slurry solids from slurry water, spalling, eliminates tripping hazards and slab. The C555 is compliant with leaving reusable water that can be used improves joint performance for all types ASTM F2659 as a non-destructive for jobsite machinery. Find us at World of ground level concrete floors, slabs electronic concrete moisture meter of Concrete for live demos! and pavements. (Sleeve design is U.S. used for preliminary evaluation of the Patent Pending.) comparative moisture condition of WOC Booth #S11020 in the South Hall Booth N2027 concrete and other floor slabs and surebuilt-usa.com screeds. Visit Wagner Meters booth 708-493-9569 (#S12555) at World of Concrete 2020 to see and try the C555 for yourself.

LATICRETE® SPARTACOTE™ Resinous Floors For The Impatient.

With fast curing coating systems, SPARTACOTE installations deliver quick turnarounds, critical when minimizing downtime is essential.

SPARTACOTE seamless, decorative flooring systems offer unparalleled integral colors, textures, and finishes through a full line of high- performance coatings that combine both decorative and functional elements. Now available in gloss and low-gloss to create attractive, durable floors featuring low maintenance, high impact and chemical resistance. These safe, non-slip surfaces are ideal for manufacturing, healthcare, education, retail, parking garages, grow rooms and more. All backed by LATICRETE technical and customer services including our industry-leading warranties.

laticrete.com 1.800.243.4788 SPARTACOTE Video Link: laticrete.com/en/resinous-and-decorative-finishes ASL Machines USA manufactures MAX Rebar Tying Tools have EZ Polish System is a faster refinement powerful propane and electric grinding revolutionized rebar tying around the process compared to traditional & polishing machines as well as world. Our latest technology is the MAX grinding and polishing. Our system industrial vacuums. Our detail-oriented Twintier RB441T, a dual wire feeding was designed to reduce time and and highly-skilled technicians are rebar tier. Features include 4,000 ties labor costs by eliminating steps from dedicated to creating the highest quality per charge, delivering the right amount conventional polishing systems. EZ machines for our customers. With years of wire for added productivity and Polish System uses 3 long-lasting tools of experience in the concrete grinding & savings. These innovative features make and 3 non-acidic chemicals that work polishing industry, our technicians know the Twintier the best and most efficient together to produce beautifully polished how to design and build machines with rebar tier in the Industry. Today, MAX floors. Sound too good to be true? Visit the customer in mind. manufactures a full line of rebar guns, us at World of Concrete to watch our VISIT OUR BOOTH and see for yourself. system work! WOC Booth #O31146 in the Outside Silver Lot Visit www.maxusacorp.com WOC Booth #O31146 in the Outside Silver Lot WORLD OF CONCRETE BOOTH #’s: C3228, O31458

Oztec BP-50a Gas-Powered Backpack

The Oztec Backpack has evolved into one of the most rugged and reliable units on the market. Equipped with a dependable Honda engine and coupled to a “speed-up” transmission, vibrator heads develop 12,000 vpm and never drop below 10,000 vpm even in the heaviest low slump concrete loads. A unique and outstanding feature of the BP-50a is a patented, totally enclosed rotary throttle, which prevents wet cement from clogging the mechanism. The rotary throttle is designed and engineered to eliminate the operator’s variable setting of the engine speed. This feature ensures that the unit will consistently produce the proper vibrations per minute resulting in optimum concrete consolidation.

WOC Booth #N2237

www.oztec.com 800-533-9055 / 516.883.8857 2020 OUTLOOK IDEA BANK

Multiquip Highlights the MQ Whiteman Line of Power Trowels

MQ Whiteman trowels were the fi rst in the marketplace, and Multiquip takes that position seriously. Always the fi rst with power trowel innovation, Multiquip will be displaying the 12 foot PRX fi nishing trowel and as well as new, small and agile ride-on trowel that is an industry changer. Come to the Multiquip booth in the central hall to see what is new in concrete fi nishing.

WOC booth number: C4537

Yes, We Stand Out. And Here’s Why. Content Licensing Since creating the densiﬁ cation and polishing markets, Ashford Formula and for Every Marketing Strategy RetroPlate have been the products to beat. Marketing solutions fit for: Ashford Formula and RetroPlate are Outdoor | Direct Mail | Print Advertising synonymous with densiﬁ cation and Tradeshow/POP Displays | Social Media | Radio & TV polishing. Many try to imitate our formulations, but never succeed. Leverage branded content from Concrete Construction to create a more powerful and Curecrete’s quality extends well beyond what’s in the drum—offering a 20-year sophisticated statement about your product, warranty on all projects, sampling each service, or company in your next marketing batch of product, assigning drum numbers, campaign. Contact Wright’s Media to find and ensuring proper application rates. out more about how we can customize your www.curecrete.com acknowledgements and recognitions to enhance 800.998.5664 your marketing strategies.

Call Wright’s Media at 877.652.5295, visit our website at wrightsmedia.com/sites/hanleywood or email us at [email protected] Company Page Number Toll-Free Number Website AD INDEX

American Concrete Institute ...... 4, 49 ...... concrete.org/certification American Shotcrete Industry Associations ...... 27 ...... shotcrete.org/WOC ASL Machines USA ...... 8, 53 ...... 866-ASL-0446 ..ASLMachinesUSA.com Bluebeam Software, Inc ...... 2 ...... bluebeam.com Bobcat Company ...... 13 ...... BOBCAT.com/ATTACHMENTS Concrete Sawing & Drilling ...... 34 ...... csda.org CONNECT-EZ, LLC ...... Inside Back Cover ...... THECONNECT-EZ.com CTS Cement Manufacturing Corp ...... 11, 51 ...... 888-307-2735 ..CTScement.com Curecrete Distribution, Inc ...... 25, 54 ...... CURECRETE.com/ELITE EZ Polish System ...... 25, 53 ...... 844-376-5474 ..EZPolishSystem.com Form-A-Drain PLUS ...... 14, 51 ...... FORMADRAINSOLUTIONS.com Foxfire Enterprises, Inc ...... 21 ...... foxfireusa.net GelMaxx Slurry Solutions ...... CS-44, 52 ...... 855-322-3335 ..GelMaxxUSA.com Hanley Wood Media 2020 World of Concrete Luncheons ...... 9 ...... worldofconcrete.com/en/events/BreakfastLuncheonsForums 2020 World of Concrete Most Innovative Products ...... 55 ...... votemip.com Concrete Construction Website ...... 28, 33 ...... concreteconstruction.net Informa Exhibitions ...... 7, 23 ...... worldofconcrete.com ...... poolspapatio.com/Attend|.com/Exhibit Josam ...... 25, 37 ...... 800-36-JOSAM.josam.com LATICRETE International, Inc ...... Back Cover, 52 ...... 800-243-4788 . . . ..laticrete.com Lignomat USA Ltd ...... CS-44, 50 ...... 800-227-2105 ..lignomat.com M & B Mag, Ltd ...... 31 ...... 877-749-9461.mandbmag.com MAX USA Corp ...... 37, 53 ...... 800-223-4293.MAXUSACORP.com McKinnon Materials Inc ...... CS-40 ...... 866-622-7031 ..mckinnonmaterials.com Metzger/McGuire ...... CS-47 ...... 800-223-MM80 ..metzgermcguire.com Multiquip Inc ...... 18, 54 ...... 800-421-1244 ..multiquip.com Nox-Crete Products Group ...... CS-47 ...... nox-crete.com Oztec Industries, Inc ...... 1, 53 ...... 800-533-9055 ..oztec.com RoMix Chemical & Brush, Inc ...... 6 ...... 800-331-2243 ..romixchem.com SOLOMON COLORS BRICKFORM ...... CS-43 ...... 800-629-0261 . . . .brickform.com|solomoncolors Somero Enterprises Inc ...... Inside Front Cover, 50 ...... SOMERO.com Stego Industries LLC ...... 17, 49 ...... 877-464-7834 ..stegoindustries.com Superabrasive, Inc ...... 39 ...... superabrasive.com SureBuilt ...... CS-44, 52 ...... surebuilt-usa.com The Malish Corporation ...... CS-46, 50 ...... 800-321-7044 ..MALISH.com Trimble Solutions USA ...... 31 ...... tekla.com/concrete Uline ...... 8 ...... 800-295-5510.uline.com Wagner Meters ...... 32, 52 ...... 800-207-2104..RAPIDRH.com Wyco Tool ...... 15 ...... wycotool.com Zimmerman Industries Inc ...... 26, 50 ...... zimmermanindustries.com

Exhibits: February 4–7, 2020 Seminars: February 3–7, 2020 Las Vegas Convention Center Las Vegas, NV

Vote Most Innovative Products at 2020 World of Concrete You won’t believe the new products headed your way. They are all great and the choice will be difﬁ cult. But which of these great products do you feel will give you an advantage and become mainstream in the market? Starting January 15, 2020, check out the latest in concrete industry innovation at votemip.com. It’s your exclusive sneak peek at the products everyone will be talking about at the World of Concrete. Tell us which ones deserve Most Innovative Products honors. It’s easy, informative and fun. Then see the MIP winners in action at the display on the WOC Grand Concourse. You’re the expert. Why not sound off at votemip.com?

ONLINE PRINT IN PERSON Vote for your favorites Check the WOC Daily Vote for the Most PRODUCED BY at votemip.com. News or the January Innovative Products January 15, 2020 to issue of CONCRETE at the MIP display in February 29, 2020. CONSTRUCTION for this the Grand Concourse, year’s entries Las Vegas Convention Center.

www.concreteconstruction.net CONCRETE CONSTRUCTION November/December 2019 55 INNOVATION

Can Innovation Solve the Labor Shortage? Tilt-up makes concrete construction more productive.

BY ROBERT FOLEY AND KIM CORWIN

THE PROBLEM IS REAL, and it’s get- find that there has been a consistent Association in 1986 not only provided ting more critical with each passing decline in the construction industry’s a vital voice for tilt-up but important- quarter. Nationally, construction productivity since the late 1960s.” ly has provided technical guidelines spending is at an all-time high—a There is, however, one stunning and training and serves as a critical recent survey by the Associated example of innovation and increased vehicle for introducing innovative General Contractors finds that 75% productivity that has changed the products into the industry. of member firms expected to add concrete industry: The advances in The following is a small sampling head count. But 78% of those firms tilt-up building technologies from the of the revolutionizing technological have found it nearly impossible to rudimentary, dull concrete boxes of advances that have led us to the cur- find and retain qualified workers, let the 1950s and 1960s to the spectac- rent state of the tilt-up industry. alone skilled craftsmen. ular multistory, Class A office build- 1980s: Laser Screed replaced The problem is compounded by ings of today. The rapid evolution in labor that is physically demanding the fact that the construction indus- tilt-up construction is a compelling and prone to injury, and Thermo- try has seen little increase in produc- example of change and dramati- mass introduced integrally insulated tivity over the past 80 years. McKin- cally increased productivity driven concrete wall panels. sey & Co. reports that “While many by innovation. The combination of 1990s: Scott Brick Systems U.S. sectors including agriculture new technologies in the construction opened a new world of architectural and manufacturing have increased of concrete structures, the applica- panel finishes that allowed thin brick productivity ten to fifteen times since tion of complex engineering analysis to be installed on concrete panels. the 1950s, current measurements made possible by computers, the 2000s: Accubrace helical anchors new products that continue to be in- made exterior panel braces possible. PHOTO: TCA troduced by manufacturers, and the 2010s: Connect-EZ recently intro- architecture profession’s embrace of duced a series of engineered devices the tilt-up concept have changed the that reduce field welding. face of the building industry. Tilt-up The labor shortage in the today is the fastest form of construc- construction industry is real, and tion, from conception to completion. with the unemployment rate at a The dynamic growth of tilt-up has historic low of 3.7% the problem is measurably increased productivity. not going to solve itself. Innovation When the labor-intensive masonry at the industry level, in the field, industry faced challenges of labor at the professional level in engi- shortages decades ago, tilt-up filled neers’ and architects’ offices, and the void. It takes one-third of the in manufacturers’ shops and plants labor and half the time to construct have been, and will continue to a concrete tilt-up wall as it does a be, the answer. As an industry we masonry wall. The productivity of one simply must embrace change. That mobile crane has replaced 10 hard- is, innovation! CC to-find skilled masons. The grassroots level of innovation Robert Foley, is co-founder of Connect- continues today in tilt-up concrete. EZ; Kimberly Corwin is president of The founding of the Tilt-Up Concrete New Chapter

56 November/December 2019 CONCRETE CONSTRUCTION www.concreteconstruction.net

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