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Which Type of Concrete is Right for Your Home?

Which type of concrete is right for your home? 

The answer to this question can be complicated because there are many different types of concrete available–each with their own benefits. 

For example, some people prefer the aesthetic appeal of decorative concrete, while others may want ready mix concrete if they’re on a strict timeline. 

In today’s blog post, we will explore all the options available so you can make an informed decision about which type of concrete is best for your project.

Decorative concrete 

This is a great choice for homeowners who want to add some extra flair to their property. Decorative concrete can be stamped or stained to create a unique look that will enhance the appearance of your home. 

It can also come in pre-designed, etched slabs and is most often used on walls. Not to mention, it’s also very durable, so you can be sure it will last for many years.

Transit mix concrete 

If you have a large job that requires high volumes of concrete, then transit mix is the way to go. This type of material is often used when contractors need to pour a large cement slab or foundation in one fell swoop. It’s important to note, however, that most concrete companies will have a minimum order amount for transit mix concrete.

Bulk dry materials 

For homeowners looking for a simple and cost-effective option, bulk dry materials can be a great choice. They’re typically used by contractors or homeowners with experience mixing concrete and are perfect for large projects.

Ready mix concrete 

Ready mix concrete is ideal for homeowners who don’t have a lot of time to spare. This type of concrete comes premixed, executing your project on a quicker timeline than custom orders like decorative concrete. 

For homeowners who are trying to create the perfect blend of strength and beauty for their home improvement projects, ready mix may be the right choice. In most cases, this type of concrete doesn’t need additives or special equipment because it comes ready to go.

Dry ready mix concrete

Dry ready mix is available for purchase in large bags. Simply add water as directed and you’ll have your own concrete in minutes that can be used for various projects. This type of concrete is often used in small projects and is well-known for its simplicity when it comes to mixing and pouring. 

Concrete has come a long way over the years, and there are now many different types available to choose from. By taking the time to carefully consider your options, you can find the perfect material for your home improvement projects. 

Port Aggregates offers the highest quality ready mix concrete in central and southwest Louisiana. It’s why we’ve been a trusted contractor for over 40 years! Contact us today to request a quote and get started on your residential project. We look forward to helping you build or renovate your home using concrete.

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What Gravel is Best for Driveways?

Gravel driveways are popular because they’re inexpensive, durable, and require little maintenance. You can choose from many different types, including crushed stone, pea gravel, quarry process, and more. 

But what gravel is best for driveways?

Each has pros and cons. Let’s take a look.

Quarry process

This type of gravel is made up of dust and pulverized rocks. After it’s poured, the dust settles into the cracks between the rocks to create a compact driveway. Because it forms a semi-solid surface, it doesn’t drain well, but it does make a great base layer for a driveway.

Jersey shore gravel

Jersey shore gravel is made up of rounded pebbles that do not compact well. That being said, they move really well under vehicles, but the driveway will need some edging so that the gravel doesn’t roll away. Because these pebbles come in beachy shades, they’re often found on the eastern shore (hence the name “Jersey shore” gravel).

Pea gravel 

Pea gravel is made up of small, round, naturally-weathered stones that can be used as a landscaping or driveway material. It’s not as durable as some of the other options, but it does have some benefits. It can create a more natural look, and it’s softer to drive on.

Because it has round edges, pea gravel isn’t as sharp as some of the other options available. This makes it ideal for driveways because cars won’t damage their tires or windows when they run over the rocks. It also has a natural look and is very affordable. 

Crushed stone #3 

Crushed stone #3 refers to gravel rocks that are up to 2 inches in diameter. It’s most often used as a sub-base layer in driveways because it provides a strong foundation for finer gravel to be poured over top. Its irregular shape allows for good drainage without compacting.

So, what gravel is best for a driveway? If you want to make sure that your driveway lasts as long as possible, then crushed stone is the most durable option. But if you’re looking for something more natural in appearance, then pea gravel is a good choice.

Whichever type of gravel you choose, be sure to consult with a professional at Port Aggregates before starting your project. We can help you choose the best type of gravel for your driveway. Contact us today to request a quote

The post What Gravel is Best for Driveways? appeared first on Port Aggregates.

Did you miss our previous article…
https://www.bellanovatravel.net/?p=293

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Your Guide to the Most Common Types of Concrete

Concrete is an integral part of the modern world. It’s used to build everything from sidewalks and driveways to skyscrapers and dams, but many people are unaware of just how many options are available. 

There are endless types of concrete, each with unique properties that make them ideal for certain applications. This article will introduce you to the most common types so you can decide which will best suit your needs.

1. Lightweight concrete

Lightweight concrete is made up of water, polystyrene particles, cement, and other additives. It’s lighter than regular concrete and is used for applications that require the least amount of weight possible, such as roofing and flooring.

Lightweight concrete also has better insulation properties and a lower density than regular concrete, making it ideal for use in climates where heating and cooling costs are a drain on the wallet. Proper installation is essential to ensure that lightweight concrete performs as expected. Be sure you choose a contractor with extensive experience using this type of concrete.

2. Reinforced concrete

Reinforced concrete is made with steel rebar or mesh that’s embedded in the wet concrete. It’s much stronger than regular concrete and can withstand greater loads without breaking.

Reinforced concrete is used for heavy-duty applications such as bridges, parking garages, and skyscrapers, and is common in both residential and commercial foundations and slabs. While it is more expensive than regular concrete, it’s also stronger and longer-lasting. 

There are two types of reinforcement: steel rebar or a fiber mesh. While both offer strength benefits over standard concrete, steel offers slightly more strength, but fiber mesh is less expensive and easier to install.

3. Polished concrete

Polished concrete is a type of flooring that’s made from regular concrete. It can be used in both residential and commercial applications and is becoming increasingly popular due to its aesthetic appeal and durability.

This type of concrete offers a shiny and smooth surface that’s ideal for offices, stores, restaurants, healthcare facilities, schools, and more.

Concrete polishing is something that should only be done by professionals because improper installation can damage the surface of your polished flooring. If done incorrectly, polishing can also void the warranty on your flooring.

4. Mass concrete

Mass concrete is poured into ready-made molds. It’s a type of precast concrete made from regular or lightweight aggregate. It’s commonly used to create dams and large foundation slabs.

Mass concrete is similar to standard concrete with just one main difference: mass aggregates are larger than standard aggregates. This makes the concrete less dense, which can be a good or bad thing depending on your needs.

5. Prestressed concrete

Prestressed concrete is made with steel cables that are stretched prior to installation using hydraulic jacks, which creates tension on the beams as they set. This compression adds strength to the concrete and minimizes cracking but also makes it more expensive.

6. Precast concrete

Precast concrete is molded in a factory setting, which allows for more precise measurements and a higher level of quality control. Because it’s cured under controlled conditions, a stronger product is yielded that is less likely to crack. It’s also easier to install than standard concrete, helping you ensure quality and efficiency and avoid installation issues. 

7. Ready mix concrete

Ready mix concrete is a type of concrete made in a plant and delivered to the job site in a ready-to-use form. It can be used in both residential and commercial applications, but it’s most commonly used for foundations, walls, and slabs.

At Port Aggregates, our concrete mixes are made using limestone instead of gravel, adding extra strength to your product. When you order from us, you can expect superior quality, lower costs, on-site quality control, prompt scheduling, fast turnaround, and more. Contact us today to request a quote

The post Your Guide to the Most Common Types of Concrete appeared first on Port Aggregates.

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The Dangers of Choosing the Cheaper Option When it Comes to Precast Concrete

Choosing the cheaper option when buying anything is always tempting, but when it comes to precast concrete, this is a dangerous mistake. 

There are many ways that shortcutting precast concrete expenses can go wrong and lead to unexpected costs. Knowing these dangers is the best way to stay within your budget and prevent your project from becoming delayed.

Here’s what can go wrong if you choose the cheaper precast concrete option.

1. Drab appearance

One thing you’ll notice about cheaper options is that they don’t look as nice. But if appearance isn’t a major concern, these materials may be fine for your needs. 

Even so, you should consider investing in nicer-looking precast concrete to give your home or business that extra boost of curb appeal. Keep in mind that if you’re putting your precast concrete outdoors, it’s going to be exposed to the environment’s natural wear and tear, but will still need to look nice for years to come.

If appearance is a priority, why risk choosing materials that can’t live up? 

2. Less strength

When it comes to strength, cheap precast concrete will never compare. Good quality materials won’t bend or buckle under pressure and are made from high-quality ingredients that toughen up over time. 

Cheaper concrete is composed of low-grade minerals that tend to break apart after just a few years. Not only does this mean more repairs, but broken concrete is also more susceptible to mold, water damage, and rust.

3. Lacking in durability

When it comes to durability, premium precast concrete is the only way to go. If you want your new structure or installation to last for decades without any signs of wear and tear, you have two choices: cheap precast concrete that will fall apart after just a few years, or high-quality, durable concrete made from ingredients that are built to withstand the test of time.

Of course, many people are tempted to choose the cheaper option just because it’s a better deal in the short term. However, they end up spending more down the line in repairs and ongoing maintenance.

Along with being more cost-effective over time, high-quality materials are also safer because they’re less likely to fall apart and collapse.

4. Limited styles available

If you want the freedom to choose between different styles and finishes, you’ll want to look at higher-end concrete. The more you spend, the more you’ll be able to customize every aspect of the installation or structure so that it fits in seamlessly with your style preferences. This means you’ll have more control over design elements like color, texture, and finish–all while using premium ingredients that will last for decades.

Some companies even offer different textures and finishes. But of course, the trade-off is that these premium materials cost more than lower quality alternatives.

5. High maintenance costs

As mentioned previously, what you don’t pay upfront for precast concrete, you’ll likely have to make up for in repair costs later. Because premium precast concrete is strong enough to withstand extreme weather conditions, less maintenance is required over time. All you’ll have to do is keep it clean and let the high-quality materials work their magic.

If you’re investing in a precast concrete structure or installation that will be exposed to extreme weather conditions, it makes sense to choose high-quality materials for the best results. At Port Aggregates, all of our concrete products are made with the finest ingredients. It’s why we’ve been trusted for over 40 years! Contact us today to request a quote for your next precast concrete project.

The post The Dangers of Choosing the Cheaper Option When it Comes to Precast Concrete appeared first on Port Aggregates.

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Interview: What Building Sustainably Looks Like for Concrete Structures and How to Achieve It

Building sustainably: there are many ways to go about it. (We’ve even discussed some ourselves right here on this blog!) But naturally, you might wonder which way is best for you.

If you’re in the concrete industry, it might feel especially critical now. After all, many professional organizations within the industry are more heavily promoting sustainable construction. And many are also establishing their own way to contribute to reaching net-zero concrete by 2050.

So, how should you contribute? And what does that even look like?

To shed some light on these questions and more, we’ve interviewed Kryton Vice President of Product Development, Kevin Yuers.

Thank you for joining us today, Kevin! Let’s start off with defining what building sustainably even looks like for concrete structures.

Building sustainable concrete structures means doing two things well. First of all, you need to build from the start with the smallest carbon footprint possible. Secondly, you need to build structures that last through their entire design without needing to be replaced or receive unnecessary repairs.

We know that concrete is a very durable building material. But we also know that its key ingredient — cement — has a very large carbon footprint.

So, it sounds like cement adds to the carbon footprint of concrete. Why is that?

You may have heard that for every ton of cement produced, a ton of CO2 is released.

Now, this is not exactly true anymore because cement manufacturers have made great improvements to their production processes and reduced this number by more than a third. But it is still a big number.

Most of the CO2 released is simply the result of the chemical reaction of turning limestone into cement, and there’s little that can be done about that.

What can be done is reducing the amount of cement you actually use in your concrete.

How can construction professionals reduce their use of cement?

Typically, the way that a concrete producer will increase the strength and durability of their concrete is to just add more cement. But there are ways to avoid that.

So, for example, many of our customers build concrete structures that are exposed to very abrasive environments, such as industrial floors, high-traffic slabs, and hydroelectric spillways. Instead of using cement-rich concrete to improve abrasion resistance, our customers add our Hard-Cem solution, an abrasion-resisting admixture.

This technology increases abrasion resistance without increasing cement content, lowering your initial carbon footprint. And because the concrete lasts more than twice as long with Hard-Cem, it can eliminate the need to replace worn-out concrete. What could be more sustainable than that?

What about countering other obstacles to a concrete’s life span like corrosion?

I can’t think of anything that contributes more to the deterioration of concrete structures than corrosion. Preventing corrosion should be a key consideration for any designer of concrete structures — especially infrastructure projects.

Again, we have to ask ourselves: what can be done to extend the life of this structure without increasing its carbon footprint right off the bat by adding more cement?

It turns out that the crystalline waterproofing admixture technology invented by Kryton in 1980 is an answer to this challenge for many structures.

Our admixture for concrete, Krystol Internal Membrane (KIM), is used today all over the world to replace membranes in water-retaining structures, basements, tunnels, and the like. But one of its lesser known advantages is its ability to delay or prevent the corrosion of reinforcing steel, which is especially a problem in places where reinforced concrete is exposed to salt like marine structures or transportation structures in cold climates.

KIM sounds like a perfect remedy for that. How does it work?

You may have heard of emerging smart technologies in building materials. These are materials that can react autonomously to events or changes in their environment by repairing themselves. Such self-healing or self-sealing is one of the ways that KIM works to protect concrete from leaks and corrosion.

If the concrete is poured with a porous area or if a crack should form, the technology from KIM reacts by growing crystals to fill the area and block the movement of water and salts from reaching the reinforcing steel. We call that Smart Concrete.

That’s great insight, Kevin! So, in short, for those looking to increase their concrete construction’s sustainability, they should strongly consider using Hard-Cem and KIM.

The post Interview: What Building Sustainably Looks Like for Concrete Structures and How to Achieve It appeared first on Kryton.

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Concrete Abrasion Resistance: The Bad, the Good, and the Better (Interview Part 2)

In our first part of this interview series, we discussed why concrete abrasion is such an issue for concrete construction and how it’s often treated. (For all the details, give it a read!) Most of the solutions discussed were shown to be complicated and ineffective. But we ended on a positive note, briefly talking about a solution that could offer a more worry-free way to increase concrete abrasion resistance.

That solution turned out to be Hard-Cem. As the only integral concrete hardener on the market, it offers a unique advantage to construction workers. With Hard-Cem, workers only have to add it to the concrete mix during batching, and that’s it. Hard-Cem doesn’t need a complicated application process and has been shown to be effective at what it does. And what it does is double your concrete’s wear life while increasing your concrete’s resistance to abrasion and erosion.

But is all that too good to be true? How does Hard-Cem actually perform? To look into it, we asked our previous contributors, Technical Director Jeff Bowman and Kryton Western Canada Territory Manager John Andersen, to give us the details.

So, why don’t we start by talking about the performance you can expect to see when you use Hard-Cem for increased concrete abrasion resistance?

Jeff: To answer that, let’s first review some of the test methods you could use for abrasion resistance.

There are several established test methods published by ASTM. But the one I’d like to highlight today is ASTM C627 (also known as the Robinson floor test based on the machine that is used for the testing).

Now, what’s really interesting about this test is that it applies a much higher load and a much longer test duration than many of the other methods that people might use.

During the Robinson floor test, Hard-Cem proved that it could double abrasion resistance compared to control concrete with 25 MPa (3,000 psi).
And early in the days of Hard-Cem’s development, Dr. Rusty Morgan, working with AMEC, recommended using this test and adapting it to increase the load and the test time to make it more useful as a test for the abrasion resistance of concrete. One of the advantages of this adaption is that because the test panel is quite large, it allows you to get a more realistic look at real-world finishing conditions that you might use for your concrete.

Essentially, during the test, wheels rotate around the concrete, allowing you to measure the depth of wear directly just by using a pair of depth calipers.

A common result for this is a very straightforward, plain concrete mix of 25 MPa [3,000 psi] with about 1.8 mm of wear depth. And after 5,000 revolutions, the depth of wear of the Hard-Cem concrete is reduced by about half compared to your plain concrete. So it creates a very significant increase in the abrasion resistance of that slab.

How does Hard-Cem perform against competing products like dry shakes?

Jeff: There are a range of dry shake materials, products, and aggregates.

Some of them do perform really well.

But if you look at our Robinson floor test results comparing Hard-Cem with different dry shakes, Hard-Cem came in with the lowest wear depth at just under 1 mm, whereas other dry shakes that were tested next to it had around 1 mm to 3 mm of wear depth.

So, you’re getting excellent abrasion resistance and you’re getting the additional advantage of a simple and reliable installation. And you’re not making any compromises on the performance of that concrete.

The Robinson floor test also showed that Hard-Cem would keep concrete wear depth to under 1 mm where several dry shake products could not.

re there any case studies about Hard-Cem’s performance?

John: Certainly! I can share a couple right now.

This first one happened 14 years ago. It was a CorLiving facility that was built half with Hard-Cem concrete and half with regular concrete. So it was a good in-service test of control concrete versus the performance you can see with Hard-Cem concrete.

The facility team later invited us in to have a look at the facility’s concrete to see how it performed. And there was a clear visual divide. In one area, it was nice and shiny with nice, straight edges on the concrete. This was the Hard-Cem concrete, and it was right next to the regular concrete, which had broken edges and was worn out and dusty.

It’s a good example of what you can see when you put Hard-Cem in your concrete.

14 years at a CorLiving facility had barely affected the Hard-Cem concrete on the left, while the untreated concrete on the right had already started to wear and gather dust.
 

Another good example is this second case study for a concrete company. They placed Hard-Cem concrete in the exit area for their concrete batch plant trucks as a way to demonstrate the performance of Hard-Cem to their customers.

Even after four years at a busy concrete batch plant truck exit, the Hard-Cem kept its brush finish, while the untreated concrete to the left had lost its surface paste.
After four years, they came back and took a look, and you could see the control concrete with the heavy machinery, loaders, and concrete trucks driving over it. It was really ground down and its concrete paste had worn away, whereas with the Hard-Cem concrete, you could still clearly see the original broom finish marks in it and its paste was completely intact.

 

 

We’ve proven that Hard-Cem can be highly effective with no application hassle. But does it have any other benefits worth talking about? We’ll look more into that on the third and final part of this interview series.

Download our e-book today to find out why the industry is moving away from surface-applied concrete hardeners.

The post Concrete Abrasion Resistance: The Bad, the Good, and the Better (Interview Part 2) appeared first on Kryton.

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Concrete Abrasion Resistance: The Bad, the Good, and the Better (Interview Part 1)

When it comes to getting a durable concrete slab, a critical part of it involves keeping the concrete resistant to abrasion. Without that resistance, construction professionals will often encounter ruts, dips, potholes, or worse in the surface of their concrete. All of which can lead to safety hazards and operational inefficiencies.

Professionals usually try to counter this with conventional surface-applied concrete hardening solutions. But these aren’t reliably effective and come with a number of setbacks.

To look into why that is, we’ve decided to explore the bad, the good, and the better parts about concrete abrasion resistance. Helping us in this discovery are two of our Smart Concrete experts: Jeff Bowman, one of our technical directors, and John Andersen, our territory manager for Western Canada. To start, let’s dive into some of the negative aspects surrounding concrete abrasion resistance.

Thank you for joining us on the first part of this interview series. Let’s start by discussing what abrasion actually is and why it is an issue for concrete in the first place.

Jeff: Abrasion describes the steady loss of material from the concrete through some sort of mechanical action. It’s generally more of a surface phenomenon.

Partial light shines down on dusty concrete that has a curved groove in it where a hard wheel has passed through multiple times.
So forces that are acting on the abrasion of concrete are usually going to be some sort of object that’s either rolling or sliding over the concrete.

And this may also be combined with foreign particles trapped between those two phases that are also gouging and sliding through the concrete.

John: When we talk about the significance of that wear and tear on concrete, we typically think about just the cost of taking the building out of service and replacing the concrete. But there’s also a cost regarding safety. And it’s not just about the people tripping and falling and encountering all other hazards because of it. There’s also an issue of breathing in the concrete dust, the cost associated with keeping the facility and machinery clean, the cost to the equipment, and the reduced productivity due to the worn out concrete.

How exactly do construction professionals usually try to resolve this issue?

Jeff: Dry shake hardeners are quite a common product for this. I’m sure many people reading this now probably use or specify them.

But for anybody who’s not familiar with them, a dry shake hardener is some sort of blend of cement and possibly some other additives and an abrasion-resistant aggregate particle, such as aluminum oxide (also called emery). And these products get broadcast in a dry form overtop fresh concrete and then worked into the surface during the final finish.

Now, certainly, these products can work and can give you a good abrasion-resistant finish if they’re installed well. The challenge that the industry has is they’re very difficult to install.

Dry shake hardeners are applied in two portions, and there’s some work that needs to be done in-between. And one of the significant challenges of this application is that it all takes place in a very time-critical period. All the steps are time-critical, and it can be very easy to miss that perfect window of opportunity.

There are just so many variables that could be happening with the concrete and with the weather. And if workers start to have trouble with it, sometimes they just can’t get a full specified amount of the dry shake applied to the concrete.

John: That’s exactly the challenge that the contractor Graham Construction faced when they were building a new pea protein plant in Manitoba. This is a massive facility with large slab pours, and they were trying to get that shake-on hardener down in that little window of opportunity. And they lost the first slab.

They eventually changed to Hard-Cem to get away from the challenge of that little window of opportunity for properly applying the shake-on.

A pea protein plant in Manitoba, Canada, sprawls over 67 acres as builders with cranes and other equipment continue to develop it.

re there other challenges that come with using dry shake hardeners?

Jeff: Another challenge that we see is that this work normally comes up fairly late in the day when workers have been at it for many hours and they’re just getting fatigued. This is a lot to put on them at the end of the day.

A gray-haired man wearing a white mask is surrounded by silica dust.
We also see that the dry shakes are very sensitive to bleed water. If there’s too much bleed water coming out when you apply the dry shake and you work that water back in, the surface will become weaker and is likely to delaminate. If you have a low-bleeding concrete, perhaps something with a lot of fly ash, there’s just not enough water there to really work it in properly. The concrete sets up too quickly.

There can also be challenges with wind. And of course, it’s very important not to use dry shakes with air-entrained concrete because the power troweling needed to really work them in properly leaves a high risk of delaminating the concrete surface. So there are many challenges to dry shake products that people might face.

There are also some products that professionals apply post-construction, right? What about those?

John: Yes, I think if you’re in Western Canada, where I live, many of these products use silicate as the base for their formulas.

Jeff: Right. When we’re describing liquid hardeners (which are sometimes called liquid densifiers), these are all some sort of silicate-based product. They work by penetrating into the concrete and reacting with the calcium hydroxide there, which is a by-product of cement hydration. That reaction turns into what is called calcium silicate hydrate gel, which is the normal hydration product of cement. It’s what gives the cement paste its strength and what gives concrete its properties. So this reaction pathway is really quite similar to the reactions you get from fly ash or slag or other supplementary cementitious materials.

That introduces some challenges in and of itself. Some suppliers of these products recommend limiting the amount of fly ash or slag you’re using in your concrete. That’s not always possible or desirable for many other reasons. Or they may recommend delaying the application for at least 28 days to allow the concrete to come up to its specified strength first so that the silicate is not competing with the other cementing materials.

Does their application work effectively?

Jeff: While they are often used or specified specifically to increase the abrasion resistance of the concrete as placed, that’s not really what they’re intended to do.

Multiple containers of liquid hardener sit in a row.
They function by slightly increasing the amount of cement paste on the surface. But cement paste is the weakest and most vulnerable phase to abrasion. Having a little bit more doesn’t significantly move the dial on the abrasion resistance of that concrete.

Now, liquid hardeners do serve an important purpose. If a contractor does have a slab that has had some challenges when they’re placing it, the surface might be poorly hydrated or weak or might have dried out too early. These products can help strengthen that surface as a remediation measure.

But they’re not really an appropriate material to specify as an abrasion-resistant material for concrete that’s been otherwise properly placed and finished.

re there other solutions that have been used to increase concrete abrasion resistance?

Jeff: Another common solution is high-strength concrete.

And why not just use stronger concrete? You get better abrasion resistance. And normally, this approach would be just using a mix that has more cement. You could use more fly ash or slag or maybe silica fume to really get that strength up and keep that water-cement ratio down real low. The concrete gets stronger, and the abrasion resistance is better. And this generally does work.

But there are some limitations.

Plumes of smoke billow out of stacks against a cloudy blue sky.
Now, the research shows that when you double the compressive strength of concrete, you can roughly double the concrete’s abrasion resistance. And there is research and literature on this.

But there can also be some consequences. Any time you are using a stronger mix, especially with anything that has more cement paste, you’re getting more hydration. That generates more heat in your concrete.

More paste means more shrinkage. More shrinkage normally means more cracking. And if you’re pouring a slab, you also now get more curling, so your floors just don’t stay as flat. And curling can result in a lot of damage and wear at the joints.

All of these things are actually really bad. They target some of the core properties that a facility owner expects of their floor. An owner wants more than just good abrasion resistance. They want their floor to perform in many other ways.

And as an added bonus, using high-paste strong mixes comes with a cost premium. Because you are using so much more cement in the concrete, the carbon footprint of that concrete can go up quite significantly.

So most popular concrete abrasion-increasing efforts don’t seem to work as well as expected. Is there a better way to get that abrasion resistance?

John: Adding Hard-Cem into concrete at the batch plant! Hard-Cem lives in that concrete paste, and that’s how it works. It increases the resistance to abrasion and erosion that way. It’s easy to apply. There are no negative effects on your plastic or your hardened concrete. It’s fully compatible and used often with air-entrained concrete, so no longer do you have to specify products like this just for indoor use. You can now use it outdoors. And it can be used in horizontal and vertical slabs, behind formwork, in precast, and in shotcrete. There’s a huge opportunity for this product to be used often in mining applications as well.

And Jeff very clearly articulated the difficulty in applying the shake-on hardeners. So no longer do the jobsites have to take all this into consideration. Basically, they can just order Hard-Cem when they order their concrete. And there’s no harmful dust exposure.

Hard-Cem’s been used for 18 years now for over 7 million m2 (80 million ft2) in all kinds of applications. And many of the top-producing concrete companies have branded their own durability concrete using the Hard-Cem admixture.

Once concrete finishers get to use this, they start to ask for it by name because it just makes their job that much easier.

A worker is holding a bag of Hard-Cem admixture ready to put in concrete mix during batching to increase its concrete abrasion resistance.

It sounds like Hard-Cem could be a much more effective solution. But how well does it perform? We’ll look into that in more detail in Part 2 of this interview series.

Click here to learn how to enhance concrete durability for superior abrasion resistance.

The post Concrete Abrasion Resistance: The Bad, the Good, and the Better (Interview Part 1) appeared first on Kryton.

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Interview: Optimizing Concrete Compressive Strength Monitoring for a Treatment Plant

Treating about 80% of San Francisco’s water since 1952, the Southeast Treatment Plant has been a critical structure for sanitizing the wastewater of San Francisco. However, the plant has been around for years, and now, many of its facilities need an upgrade.

Knowing this, the San Francisco Public Utilities Commission has started modernizing the plant. Part of this transformation includes replacing the treatment plant’s headworks facility with a new one. That will ensure the treatment plant will be able to more effectively remove debris and grit from the water while meeting the current seismic standards.

To construct this more modern headworks facility, the San Francisco Public Utilities Commission has collaborated in a joint venture with The Walsh Group Ltd. and Sundt. And we are pleased to note that we are helping The Walsh Group Ltd. optimize their work in this venture with our Maturix Smart Concrete Sensors.

Our Maturix specialist, Kris Till, got to discuss this in a recent video interview that he conducted (which you can see here). And in this article, you’ll get to see that discussion along with some extra details on the topic.

Why don’t we get started by having you tell us who you are, who you work for, and what you’re building?

My name is Tanner Santo. I’m a superintendent for The Walsh Group here in San Francisco, California. We are building the new headworks for the Southeast Treatment Plant. It’s going to be up to a 300-million-gallon-per-day capacity in the wet season. We’re looking at probably a good two years of structural concrete, which will primarily be my focus.

What do you consider to be the most important factor when building a project like this?

I think one of the biggest things I look for as a superintendent is to maintain efficiency while also preserving quality. There are a lot of moving parts and challenging logistics on this project. And what we need to do is just get our crews into a rhythm.

So, why are you monitoring concrete in this project?

That’s actually a very good question. We’re doing a lot of vertical walls on this job. I think we have 300 to 400 different wall placements. And the big thing for us is that we cannot strip those forms until we reach a minimum compressive strength.

What would you have done in the past to monitor your concrete compressive strength?

So, in the past, in situations like this, we pour a wall, say on a Monday, and take a bunch of concrete cylinders. By Tuesday morning, they’re sent off to a lab. If I want early breaks to remove the formwork, I need to take extra cylinders.

The extra cylinders can be costly when you talk about hundreds of wall placements. So taking and breaking extra cylinders for every placement adds up very quickly.

What’s even more of a hassle is getting those break results. So if I put in a 30-foot-tall [9.14-meter-tall] concrete wall on a Monday, Tuesday morning, I’m waiting on a testing lab to give me early breaks back, and what I need them to tell me is that the concrete has reached a minimum strength. So in that morning time when I’m waiting for a break result or for the testing lab, I have a crew of guys who are basically not being efficient. They can’t strip the formwork yet.

nd what’s your current concrete monitoring process like now?

We put a few thermocouples with the Maturix Sensors into the wall at the time of placement, and thanks to the maturity curve that we’re able to calculate with the help of CEMEX, our concrete provider, we actually get a live readout of compressive strength. If we had never run this maturity curve for these sensors or monitored the live compressive strength with the sensors, I don’t think we ever would have realized how quickly we were getting concrete strength on this job.

It gives me a lot of temperature data as well. Had those sensors not been there, we wouldn’t have realized that we are working with a relatively hot mix. We now exercise some caution with some of those thicker placements that I don’t think we ever would have previously because we just wouldn’t have known what type of internal temperatures we were getting on this job. That information alone has been a big help as far as planning and scheduling goes.

It’s even so streamlined that I have notifications set up to my cell phone. I’m not waiting on a call from a testing lab. I’m not hounding a testing lab. I actually get a ding on my phone, but on this project, it’s a bit unique. It’s actually kind of in the middle of the night or the early, early morning when it tells me that a wall has reached 1,250 psi [8.62 MPa]. That way at 7 am, when the guys show up to work, we’re not waiting on anything. We immediately get to work taking the forms off. I know the wall has reached a compressive strength where it’s safe to do so. There’s really no second-guessing anything. And that helps with the logistics of cranes and organizing manpower.

Why did you specifically choose Maturix?

What made Maturix the number one choice was just the cost-effectiveness of it. A lot of the competitors have one-time-use sensors where you’re paying up around $100 a sensor and you embed it into the concrete. In every single pour, that’s $100 down the drain whereas Maturix technology is actually better because I don’t have to go around and capture the data with Bluetooth. It’s all done over a cloud network. It’s sent directly to my phone like I mentioned. I don’t have to pay someone to go around and collect data via Bluetooth. So in reality, I’m paying less for a better product.

So it seems Maturix offers cost-effective concrete compressive strength and temperature monitoring. It also documents everything related to this. Has that helped you with quality control procedures?

Yeah, definitely. It just basically organizes all our pours. I mean, I can go back to stuff I poured a month ago and see that Maturix records the exact time of placement.

What would you tell someone who is considering Maturix?

It’s streamlined. It’s easy. As far as cost-effective, it’s not even close compared to the competitors out there with the one-time-use sensors. And the labor you save in collecting the data is also a huge cost saving as well. So we’ve just been very happy with what these sensors have provided for us here.

Thank you so much for taking the time to talk with us. We really appreciate it.

No problem. You guys are helping us out a lot on this project. We got a good thing going here, so I’m happy to help out.

*Banner photo by Pi.1415926535, CC BY-SA 4.0 , via Wikimedia Commons

The post Interview: Optimizing Concrete Compressive Strength Monitoring for a Treatment Plant appeared first on Kryton.

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Choosing a Waterproofing Strategy for Below Grade Applications: A Fourth Alternative

Considering the right waterproofing strategy from the design stage is crucial for the success of below grade projects. However, there is no one right answer.

So when faced with this decision, the designer of a project will often start by selecting from several types of external membranes. These include unbonded, fully bonded, and compartmented systems. Each of which will affect the outcome of a project differently.

But no matter their choice, a designer will have many variables to consider.

That can be difficult to navigate. So to help you determine the best strategy for your project needs, let’s look at the factors that affect waterproofing decisions and outcomes and whether there’s a better alternative altogether.

The Factors That Affect the Selection and Outcomes of the Three Membrane Types

Designers typically select one of the three waterproofing membrane types based on the following factors:

Perceived risk of using the systemAccessibility for repairing system defectsQuality control tools of the selected systemOverall cost

Perceived Risk

Out of the three waterproofing membrane categories, there is one that is seen as less risky.

A bitumen waterproofing membrane rests partially unrolled on the ground.

Many View the Use of Fully Bonded Systems as the Reliable Waterproofing Strategy

The idea is that in case of failure, water cannot travel freely between the membrane and structural concrete, so any damage will be localized. That minimizes the cost and scope of the repairs needed.

Despite that big advantage, fully bonded systems also have their drawbacks. They are not flexible when bonded. They cannot bond properly to the structural concrete if not applied properly and in dusty conditions. And most importantly, these bonded systems are thin, making it easy for them to get damaged.

Still, these particular systems tend to remain less risky than others, even when it comes to application errors (see Figure 1).
On a graph that compares risk and application errors, unbonded membrane systems are the most at risk while compartmented membrane systems are at second place and fully bonded membrane systems are last.

A group of construction workers are working on pouring concrete at a worksite.

That Risk Changes, However, When Bad Concreting Practices Are Involved

Note how the dynamics change with bad concreting practices. The risk associated with application errors deviates as follows (see Figure 2).

The risk of application errors change when bad concreting practices are involved, making fully bonded membrane systems a bit riskier but still not as risky as unbonded membrane systems.

In this scenario, the bond between the membrane and structural concrete would have been compromised. Once that occurs, a fully bonded system will become riskier than a compartmented system due to the following reasons (among others):

Membranes in fully bonded systems tend to be thinner than ones in compartmented systemsThey don’t have horizontal and vertical protection as many compartmented systems doThey also do not have the same reactive system for repairs with flanges in each compartment

No matter the system, however, the risk related to application errors is shown as much steeper (as seen in Figure 2) when there are bad concreting practices involved. You need only compare the risk to a project with good concreting practices to see the significant impact (as shown in Figure 1).

ccessibility for Repairing System Defects

For stakeholders who prefer a waterproofing system that workers can access for repairs if something does go wrong, compartmented systems are perceived as the best (see Figure 3).

Why is that the case?

It’s mainly because it is possible to attempt to repair each leaking compartment of the system with injection flanges.

As for the other waterproofing systems, the unbonded one remains the riskiest, as it would be very hard to determine the source of its leakages.

Again, what adds to the complexity of just selecting the best perceived waterproofing system is a poor concreting application.

In this case, combining a poor concreting application with a compartmented system means water is more likely to migrate between compartments. That will increase the risk of the compartmented system’s waterstops not bonding adequately to the structural concrete. At the same time, isolating individual compartments in the system and repairing them with flanges will become less effective, since the water will be migrating between adjacent compartments. And that leads to a change in risk assessment (as seen in Figure 4).

The risk to application errors graph shows poor concreting practices increase the risk of compartmented membrane systems so that they are closer in terms of risk to fully bonded membrane systems.

Quality Control Tools

For stakeholders who depend on quality control tools to ensure that a membrane is installed properly, a polyvinyl chloride (PVC) compartmented system might be more appealing. Usually coming with the desired quality control tools, it has an edge over most types of fully bonded and unbonded systems.

The quality control tools that a PVC compartmented system typically comes with include a double-wedge welding of membrane overlaps. And that’s followed by pressure testing to guarantee that the overlap is properly welded.

Other quality testing measures for the overlaps in this case might include vacuum testing and spark testing.

All the above are great tools in theory. However, this quality control edge tends to be more theoretical than realistic in many instances. Such instances include (but are not limited to) vertical membrane applications. After all, it would be very unpractical to make a double-wedge welding joint and test each individual joint in vertical (or otherwise complicated) applications.

Overall Cost

Cost per system is not universal and differs in each market. But in general, an unbonded system is the cheapest, while fully bonded and compartmented systems tend to be more expensive.

However, when we consider what I call the membrane system lifetime value, cost assessment tends to be more complicated. The lifetime cost would include the initial cost of the system, the expected life of the system, and repair costs of the membrane over the service life of the structure. Once again, concreting practices play an important role with the associated costs of repair and replacement. Choosing a waterproofing system based on cost is therefore a complex decision that includes many variables, which are hard to quantify.

A group of construction workers at a worksite are helping to pour concrete for a project.

Why Concreting Adds Complexity to These Factors 

Waterproofing is an interconnected network of activities. So rationally selecting the appropriate system depends on many variables. A common variable that adds to the complexity of the selection and on the consequences associated with that selection is the quality of the concrete. That in turn is a function of the structure’s concrete mix and application. Therefore, it is impossible to assess the performance of the waterproofing membrane system in isolation without considering the concrete’s quality.

A construction worker is pouring KIM into concrete at the time of batching.

How to Simplify and Improve a Waterproofing Strategy with a Fourth Alternative

The fourth alternative is not a compromise between an unbonded, fully bonded, or compartmented system. A fourth alternative is a better waterproofing strategy. It’s a waterproofing solution that simplifies a designer’s choice while providing more predictable outcomes.

Simply put, the fourth alternative is to design and construct a waterproof structure that can sustain itself without external protection. That eliminates the concern of that external protection defecting or failing, as it transforms the concrete itself into a solid waterproof barrier. It also minimizes the need for extra labor or application time, as there is no membrane to install.

But how is this waterproofing strategy possible? What makes it work?

It all functions off the following principles.

The Structure Should Be Waterproof for Its Entire Intended Service Life

This is attained by using quality concrete, proper jointing systems, and adequate reinforcement.

The latter follows conventional construction methods, so let’s focus on those first two aspects.

To obtain quality concrete in this case, builders need to ensure that they use a suitable mix that is permanently waterproof. An easy way to do this is by applying a reactive waterproofing admixture, such as Kryton’s Krystol Internal Membrane
™
(KIM), with the established best practices for mixing, placing, and curing concrete.

Once added directly into the concrete, KIM disperses Krystol technology throughout the concrete mix, which remains dormant until water is nearby. When in the presence of water, the chemical technology reacts, forming interlocking crystals to block pathways for water in the concrete. That reduces the concrete’s permeability, shrinkage, and cracking. It also improves the concrete’s ability to self-seal for the rest of the structure’s life span.

But what about proper jointing systems?

Special consideration should be given to jointing details, including construction, expansion, and control joints. Using a combination of physical and chemical barriers is recommended for long-term performance. A good example of this is the Krystol Waterstop System. It offers three levels of protection for all jointing details. Depending on the level of protection chosen, the system might make use of two types of waterstops (one for sealing joints and one for crack control), a crystalline slurry that uses Krystol technology for concrete joints, and a crystalline grout.

For Extra Reliability, Designers Need to Determine a Suitable Repair Strategy

With a reliable waterproofing admixture and jointing protection system, a concrete structure should be quite safe.

But it’s important to include redundancies into a waterproofing system. It’s what gives a structure extra protection in case the situation does not go as planned. But to include those redundancies, designers need to consider a suitable repair strategy.

The repair strategy should be based on durable materials that are compatible with concrete. It should not be cosmetic and planned for the short term as it has to be able to fix the problem at its source. Otherwise, the problem will remain present, causing more damage in the long run.

dditional Protection Needs to Be Considered When Handling Projects That Are Considered High-Risk

These can include liveable basements, museums, and other structures where the cost of repairs is very high.

If that is the case for a project, a designer could add a membrane system to the waterproof structure. Selecting one will depend on the previously mentioned factors. But in general, as discussed earlier, the quality of concreting practices will affect how well a membrane type will perform. So it’s important to maintain good concreting practices no matter which type of waterproofing membrane system is chosen.

In short, the fourth alternative is a waterproofing strategy that fundamentally relies on a self-sustained waterproof structure free of application and additional labor concerns, a suitable repair strategy, and when necessary, the extra protection of a waterproofing membrane system.

Free e-book! Download it today to learn about the four aspects to consider when specifying crystalline waterproofing admixtures.

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Avoiding Concrete Cracks in the Winter: How to Prepare Your Concrete

One of the most dreaded things about winter is its damaging effects on concrete. This can be a costly and frustrating problem, but it doesn’t have to be! 

There are numerous easy ways to help avoid concrete cracks this winter. Follow these steps to prepare your driveway or other concrete slabs for the cold months ahead.

Seal your concrete surfaces 

In winter months when snowfall and low temperatures freeze the top of your concrete, frost damage can occur if they are not sealed. Sealing your concrete protects the surface and makes it easier to remove any ice as well. 

Remove debris

Regularly scraping away any leaves that fall onto your concrete as the seasons change is vital to protecting your driveway or other concrete fixtures. Leaves and other organic matter will prevent your concrete from getting the proper exposure to sunlight it needs in order to avoid freezing.

Repair any damaged concrete

If your concrete has become damaged or is already cracking, you need to take care of it as soon as possible. 

Cracked concrete exposed to freezing temperatures can cost thousands of dollars to replace and is likely to continue deteriorating over time if you do not repair it before temperatures continue to drop. 

Be sure to inspect all areas of your property that have concrete. It is possible that your gazebo, deck, or walkway might need replacement too.

Be careful with salt 

Using too much salt as a melting agent can actually damage your concrete, causing it to become brittle and more likely to crack. It should only be used in moderation. Fortunately, in Louisiana, this shouldn’t be too much of a concern for us. 

If you follow these steps, you can avoid the nightmare of having to replace cracked concrete this winter season. Don’t wait another day to start protecting your concrete. 

With the Louisiana weather being as unpredictable as it has been the past couple of years, there’s no telling what this winter will bring. Start taking steps to protect your driveway now and contact Port Aggregates for assistance. We look forward to helping you keep your concrete safe this winter!

The post Avoiding Concrete Cracks in the Winter: How to Prepare Your Concrete appeared first on Port Aggregates.