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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.

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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.

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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

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Did you miss our previous article…
https://www.bellanovatravel.net/?p=234

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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.

The post Choosing a Waterproofing Strategy for Below Grade Applications: A Fourth Alternative appeared first on Kryton.

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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.

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Convert Your Concrete Slab from a Maintenance Liability to an Asset

When you think of concrete, it’s likely not long before you’re thinking about its durability. It’s one of the more well-known advantages of the material. And it’s why many choose to use concrete in construction. After all, no one wants to build with a material that couldn’t withstand the outside elements. So we turn to that concrete durability, relying on it enough to make concrete one of the most consumed materials on the planet, second only to water.

But concrete isn’t invulnerable. Depending on its mix, you could have a maintenance liability on your hands. Luckily, there is a way to avoid that. All it takes is being aware of how you can convert your concrete slab from a maintenance liability to an asset.

Keep in Mind That Slabs Can Be Prone to Wear and Tear

The first step in the right direction is to remind yourself that while durable, concrete slabs can still be prone to wear and tear.

It’s why you look for concrete hardening products. They’re meant to add an extra layer of protection to the concrete’s surface, sheltering it from abrasive and erosive forces that might otherwise degrade the concrete.

You can probably think of quite a few culprits responsible for this wear and tear. But as a refresher, let’s look into the specific types of abrasion and erosion you’re likely protecting your concrete from.

Number of Abrasive Forces Can Cause This

As noted in our latest e-book (which you can download and check out for yourself here), there are three specific types of abrasion-only wear:

Sliding abrasion — Also known as two-body abrasion, it’s what happens when a hard object slides across concrete. As it moves, the hard object will begin to gradually bore into the concrete, removing a bit of its surface each time. So if you have skids or some other item with a hard material moving back and forth over your concrete frequently, you’ll start to notice a rut in its surface.

 

Foreign particle abrasion — For any concrete projects that deal with vehicles, you’re sure to come across foreign particle abrasion. That’s because as the vehicles travel over the concrete, hard particles get trapped between the vehicle tires and concrete surface, and that wears down both materials simultaneously.

 

Rolling abrasion — A common sight in industrial spaces, rolling abrasion is what happens when wheels under a heavy load roll over a concrete surface. These wheels might come from carts, forklifts, or other wheeled equipment. But whichever one it is, over time, their movement over the concrete surface wears that surface out and creates noticeable dips in the concrete.

Erosive Forces Can Also Cause Similar Damage

One of the more common types of erosive wear is actually a combination of abrasion and erosion. And it’s often seen in hydraulic projects.

Why?

Well, these projects are typically ones that are surrounded by fast-moving water, such as dams and spillways. So they are more likely to encounter the abrasive effect of debris in the water grinding against their concrete surfaces. This debris might come in the form of silt, sand, gravel, rocks, or even ice. And while it’s roughing up the surface of the concrete, the surrounding water rushing by is gradually causing the concrete to erode.

A pale door shadowed in darkness stands ajar, showing an alarmingly red room past it.

That Can Open the Door to Various Costly Risks

If either abrasion or erosion starts to seriously affect your concrete to the point that you can see the damage, it can create a safety hazard, disrupt operations, and increase maintenance costs.

For Floor Slabs, That Can Involve an Increased Danger of Slipping, Tripping, and Falling

All those dips and ruts in concrete flooring caused by abrasive wear? They can pose a threat to your team’s personal safety.

While for a time, you might be able to work around the uneven flooring, you or someone else on your team is inevitably going to slip, trip, or fall. In fact, it’d be close to a statistical anomaly if you didn’t! Slips, trips, and falls make up a third of lost-workday injuries according to the Centers for Disease Control and Prevention. And as EHS Today notes, the primary cause for more than half of these injuries is due to an issue with a walking surface. So you can imagine the risk you take with keeping that uneven floor!

The cost of not implementing preventative measures for this kind of risk for businesses in the United States of America (USA) alone is about $70 billion a year overall in compensation and medical fees for workers.

For Road Slabs, That Means Traffic Accidents

Similar to how uneven flooring can pose a risk to people walking over it, uneven roads can be a risk to those driving.

Initially, that unevenness might be a slight difference in road surface from all that foreign particle abrasion. But eventually, that slight dip might lead to potholes or a fully uneven road. It also increases tire wear, making the vehicles on the road less efficient and safe to use.

All of which increases the risk for roadway accidents. Potholes on their own cause around $3 billion in vehicular repairs annually in the USA. And in Canada, each year, the cost for drivers as a whole is increasing by that same amount because of increased vehicular repairs and maintenance and general vehicular damage due to poorly maintained roads.

Hazards like potholes pose an even greater risk for those on motorcycles and bikes.

Those on motorcycles, according to the Motorcycle Safety Foundation, may crash when encountering potholes. That can be a significant concern as motorcycle incidents have a 29% higher fatality risk than ones that occur with automobiles and light trucks.

For cyclists, they can end up with permanent nerve damage. But that’s not the worst-case scenario. Much like those on motorcycles, cyclists have a higher fatality rate when it comes to crashing. For instance, since 2007, in Britain, potholes alone have killed at least 22 cyclists and seriously injured another 368.

The Potential Damage Doesn’t Stop There Either

Of course, worker injuries and vehicular damage aren’t the only costs to consider when facing abrasion and erosion damage. You also have productivity, equipment, and structural loss to worry about.

For instance, workers operating forklifts on an uneven surface are likely to drive more slowly to avoid tipping over, reducing worksite productivity. And if they don’t? You’ll likely be paying to repair or replace that forklift and any items it happened to be carrying.

Using fully automated equipment won’t do much to overcome this obstacle on its own either as an uneven surface can prevent it from operating properly.

And what about structures? With enough abrasion and erosion, owners will have to close down for repairs and replace large sections of concrete structures, from floors all the way to hydro dams. All of which is extremely costly to any business and doesn’t endear owners to the concrete they used.

A construction worker is adding Hard-Cem into his concrete mix during batching.

But Your Concrete Slab Doesn’t Have to Be a Maintenance Liability

You just need an effective concrete hardening solution.

Your first thought might be to use conventional surface-applied concrete hardeners like dry shake hardeners or liquid hardeners. However, those come with a number of setbacks.

Dry shake hardeners, for one, come with a complex application process. It’s not a one-and-done deal. Instead, a worksite team has to prepare the worksite first. That means removing excess concrete and preparing the remaining concrete. Then, depending on your chosen hardener’s material, you may have to take an extra step and use a wood bull float and then a machine float. After that, the team can finally move on to actually applying the dry shake hardener, which will cover a couple millimeters of the concrete’s surface.

However, even that part isn’t without complications. Dry shake hardeners can only be applied during a specific time and type of weather. Pick the wrong time and you can end up with delaminated concrete or an inability to even apply the dry shake.

At the same time, this hardener makes use of a toxic material known as silica dust, which means a worksite team needs to meet the proper safety measures to keep workers safe and comply with legal restrictions.

On the other hand, while not as frustrating to apply or as hazardous as dry shake hardeners, liquid hardeners are often misrepresented. They were first sold as dust reducers to help with defective concrete slabs that had a dusty surface. But now, they’re expected to harden concrete, which they do very poorly.

(For more reasons and data on why these aren’t effective solutions and more, take a look at our e-book on the topic!)

So, what can you use instead?

pply Hard-Cem to Increase Your Concrete Slab’s Resistance to Wear and Tear

Unlike any other concrete hardener on the market, Hard-Cem is an integral hardener. That means it applies its hardening properties throughout a concrete mix to form one solid abrasion- and erosion-resistant material. Essentially, it’s an admixture that you add into the concrete mix during batching. At that time, the admixture will permeate the entirety of the mix, giving it a harder concrete paste and reducing fine and coarse aggregate exposure. It does all this to help the concrete effectively resist abrasion and erosion.

Your Concrete Slab Will Gain Many Other Benefits as Well

More specifically, when using Hard-Cem, you’ll double the wear life of your concrete.  Because it does last that long and can resist abrasion and erosion, Hard-Cem-treated concrete comes with fewer maintenance fees. So you won’t need to resurface or replace your concrete as often. And you won’t need to use as much cement. That can increase your savings on carbon emissions by as much as 40%!

In some cases, this has even helped construction teams earn LEED certifications.

All you need to do to get these advantages is to throw the admixture and its dissoluble bag into the concrete mix during batching. There are no extra application steps, toxic silica dust, or inefficiencies to worry about. So you don’t have to spend money or time on hiring extra labor or managing application errors. Hard-Cem does all the heavy lifting, giving your mix the thorough durability it needs as soon as it’s added.

Hard-Cem also offers incredible versatility. It can work for a variety of projects and help harden horizontal, vertical, and inclined concrete. And it is the only hardener capable of being used for air-entrained concrete.

In short, it increases your concrete’s durability, speeds up your construction, reduces application costs, provides universal compatibility for different concrete mixes, and makes it all more sustainable.

A construction worker is guiding concrete mix down into the area it needs to be poured in.

It Just Takes the Right Concrete Mix Ingredients

With Hard-Cem added into your concrete mix, your concrete slabs will be an asset to your project. They’ll need less maintenance over the years, help you reduce your carbon emissions, and most importantly, keep abrasion and erosion at bay to keep your concrete structures standing for as long as possible.

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

The post Convert Your Concrete Slab from a Maintenance Liability to an Asset appeared first on Kryton.

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What is Reinforced Concrete?

A lot of you will be familiar with reinforced concrete as a building material, but may not be aware of the finer details. Commercial concrete is often a good solution for building work, we will be discovering a bit more about why this is the case, and the best ways to go about using the material for your building projects.

Everything You Need to Know About Reinforced Concrete

Commercial Concrete

This is concrete used as part of a building project, often used to create or enhance business facilities, industrial buildings, warehouses and retail stores. In an average building, you will find commercial concrete in plenty of spaces, such as the walls, floors and even some architectural details. A large majority of commercial buildings would have been put together with heavy use of commercial concrete. Like domestic concrete it has many benefits when used on a building site, durability being one of the most obvious.

Domestic Concrete

Domestic, or residential concrete usually has less demand placed on it in terms of structural performance and durability, but in itself, it is still considered a durable building material. Domestic concrete floors and pavements usually require a lower strength mix design and lighter reinforcement than commercial concrete.

Concrete Pumps

The purpose of a concrete pump is to have a tool that can convey liquid concrete. This works by having one piston drawing liquid concrete into a cylinder from a hopper while the other piston simultaneously pushes concrete out into discharge pipes. There will be a valve which can determine the cylinder that is open to the concrete hopper and the one which is open to the discharge pipes, which gets switched over each time the pistons reach an endpoint, with the process continuing with the first cylinder now discharging and the second drawing fresh concrete from the hopper.

Concrete Services

If you need to deal with reinforced concrete there are a couple of things that are crucial to consider. You need to make sure that if you are laying the material yourself you know what you are doing with it. You must also make sure that the concrete is of a high-quality standard. You must have the facilities to mix it correctly as well as an appropriate skill/strength level to physically handle it/the required machinery.

Alternatively, you may need to use the services of a professional concrete company, like Base Concrete, to prepare and lay the concrete and get your building project completed. Commercial concrete can be a great asset to all sorts of projects and can be purchased with some very good deals, just make sure you are only ever involved in using the services of professional and trusted companies. It is almost a guarantee that your area will have quite a lot of concrete services operating in your area where you can purchase your desired amounts of commercial concrete or have a service bring around the material and lay it on your behalf.

So, for all your concrete needs, contact Base Concrete today on 01442 389105. For more details, visit our contact page.

The post What is Reinforced Concrete? first appeared on Base Concrete.

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Why Concrete is a Great Choice for Floors

You may just see concrete as a flooring option that is a pretty standard arrangement, one that places tend to opt for if they can’t think of a better choice. But some noteworthy reasons make concrete a great choice for flooring, it can elevate a stepping space to the next level… Let us take a look at 6 great benefits of concrete flooring and how it can transform the look of your property.

Strength 

If you know anything about the strengths of concrete, you will know that it’s a very durable mixture indeed. We’re talking about a material that can withstand very high volumes of weight, with strong pressure presenting no issues whatsoever. Heavy equipment and vehicles would not be enough to make a dent on a concrete floor. So a concrete floor can easily take all the foot traffic and moving of furniture that the average household is likely to take part in regularly without any issues!

Long-lasting

This durability means that the concrete will hold up and last for years to come. Especially if the concrete flooring is well looked after and sealed, you can expect it to last for a very long period before it becomes anywhere near being worn down. And even when the texture and colour begin to change with age, a long way down the line, that adds a bit of ‘character’ to the style of the flooring and is not a practical issue unless it actually becomes damaged in any respects.

Plenty of design options

Concrete does seem to be stereotyped as a boring flooring type, but that is quite unfair. Designers have come up with a wide range of options, with absolutely loads of different colour and textual effects to choose from. And don’t forget you can stain or paint the surface of concrete for your desired effects and also opt for other specialities such as polished concretes.

Reasonable 

If you’re cost-conscious, whether you’re looking to purchase domestic concrete or require flooring for office space, it remains one of the more economical options available. The clever aspect is that you can choose a faux floor pattern that resembles the style of a much more expensive flooring type for a fraction of the cost.

Easy to Maintain

Another big benefit of concrete is that it’s very easy to maintain. As mentioned, it will keep even better with a seal of some kind, a protective sealant that should be reapplied every 3-9 months on average. Regular sweeping and mopping will help keep the concrete looking fresh and new, but other than that, not much maintenance is required. Polishing your concrete is also a great way to keep it looking its best.

Good for Indoor and Outdoor

A final benefit of concrete flooring is it’s a reliable choice for both indoors and outdoors, so you can have it set up in your home or garden area.

You should enjoy selecting a great looking concrete flooring style, but there is also an alternative option. Consider hiring a mini concrete mixer which for a very small daily fee can produce your required amounts of concrete from the comfort of your garden! This can work out to be a very affordable way of getting the job done! So, for all your concrete needs, contact Base Concrete today on 01442 389105. For more details, visit our contact page.

The post Why Concrete is a Great Choice for Floors first appeared on Base Concrete.

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The Many Uses of Concrete

Where would we be without concrete? It’s one of the most versatile and essential products for almost all construction projects across the world. It’s a substance that fills our world and can be seen in almost everything we see, but also one that is so easily overlooked.

There are so many uses for concrete. Its applications and uses are more varied and more widespread than you can imagine. There are over 20 different types of concrete that are used in a multitude of construction projects, but what are the most popular applications for it? What is it that makes concrete such an advantageous material to use, and how is it used in both domestic and commercial developments. Let’s take a look.

Origins of Concrete

Concrete, in one form or another, has been with us since 6500 BC. It can be traced back to what is now, the United Arab Emirates, where Nabataea traders created concrete floors, houses and even underground cisterns.

The Egyptians were using it to build the pyramids in 3000 BC, where they used mortars of lime and gypsum to create their version of cement. It was also used, not surprisingly perhaps, to help construct the Great Wall of China. It didn’t become concrete, at least what we recognise it as today, until the 1800s, but since then, its uses have grown more and more.

Buildings

For any of us living in a house or working in a building, it’s likely to be made from brick and mortar to some degree. In the UK, it took off after World War II as part of the rebuilding efforts. Nowadays, it’s probably the most popular application of concrete in the modern age and will be for centuries to come.

Foundation

Even if the building itself is more steel and glass, its foundations will be made from or secured in, concrete. Concrete is so popular because it won’t burn or rot, which means that the foundation is going to maintain its strength and rigidity for many years.

Roads and Bridges

As we move up in the world, the very streets you walk on and the bridges you use to cross those roads will also be made of concrete. Again, concrete wins against other materials because of its durability and safety. It might not be obvious, but another advantage of concrete in these environments is that it offers better reflectivity at night. Of course, it’s not just pedestrians it has to support, but because it can hold heavier weights, such as cars and trucks, it’s the perfect material to use.

Why Concrete has so Many Uses

The applications for concrete don’t stop there. They are only the start. Concrete is so popular in different projects simply because of its adaptability. It’s not sensitive to moisture, can be shaped and moulded into almost any design, affordable and is recyclable.

It has a very long lifespan, doesn’t release any dangerous organic compounds and is just as safe for inhabitants. It’s easy to forget the difference concrete has made to our world, but just look around and you’ll see that it’s everywhere.

Contact Us

Thank you for reading this blog post. Should you be looking for any mixes or perhaps ready mixed concrete itself, then we can deliver it straight to your door. So, if you have any upcoming tasks, then get in touch today on 01442 389105 or visit our contact page for more details.

The post The Many Uses of Concrete first appeared on Base Concrete.