Mastering how to grind and polish concrete countertops is critical to any project’s successful completion.Concrete is a mixture of cement, rock aggregate, sand, and water. Cement by itself is very brittle, but when rocks and sand are added, a matrix is formed that strengthens the mix. The cement is like the glue, and it fills in the small space between the aggregate and sand. This makes concrete much stronger than cement on it’s own. Because the rock aggregate in concrete mixes are quarried regionally, the types of rocks you see will be different depending on where you are in the world. The concrete pieces in this guide are made from a 5000 psi. concrete mix produced with Northern California aggregate.Normally when casting concrete, the cement paste forms a uniform layer on the surfaces of the piece, producing a piece that is one solid color with minor variations. This is referred to as a cast-finish. The cement layer can be removed with very light polishing. This will begin to expose the fine sand in the mix, called a light-polish. Deeper polishing will expose the rock aggregate and produce a ground-finish. Very little material needs to be removed to expose the aggregate and achieve a ground finish (about 1/16″).This guide will show you how to polish concrete countertops. There are a range of finishes possible from a single piece of concrete. Normally polishing is accomplished using a variable speed concrete polisher with a set of diamond sanding discs. The polisher is usually water fed and is attached to a normal garden spout. The water helps cool the pads down and also keeps dust to a minimum.

Concrete surfaces such as floors, pipes, bridges, and parking structures all have unique requirements often specific to application environment and timing. Cardolite’s line of products for both concrete primers and topcoats is designed to specifically address extreme conditions where other materials might cause failure. By widening a product’s application range, formulators can have the confidence their coatings will perform even in the face of often uncontrollable conditions.Formulators can choose from a broad line of modified and unmodified phenalkamine and phenalkamide curing agents that are designed to address common challenges in concrete coatings. Cardolite’s curing agents for primer epoxy systems have excellent adhesion to damp and dry concrete, early water resistance, quick hardness development, and fast and low temperature cure that allow for a wider application window, quick return to service, and lower risk of coating failure. In addition, some Cardolite curing agents can be used in epoxy top coatings due to their improved gloss and color retention while still maintaining excellent mechanical properties.Selecting the appropriate curing agent will depend on desired concrete coating properties such as target volume solids, cure speed, film properties at certain conditions, color, application method, and overall performance. Many of our curing agents are ready to "mix and spray" without the need of additional accelerators, co-curing agents, adducting, or heating of the application area.A comprehensive list of CNSL curing agents available by systems solids can be accessed through the links below. Curing agents suitable for concrete primers, self-levelers and top coats are indicated by "CP", "SL" and "TC" respectively in the applications column.·  Medium Solids Systems·  High Solids Systems·  Solvent Free SystemsCardolite offers cardanol derived epoxy resins, diluents, and modifiers that can be used to lower viscosity, impart flexibility, or accelerate cure without adversely affecting other properties. Selection of the appropriate product will depend on desired reactive functionality, solids, viscosity, color, cost, and cure acceleration. Please select the links below to learn more about these products.

        Concrete resurfacing is available in a wide range of colours, designs and textures, meaning if you fancy a change, you are free to do so. Options include sandstone, granite, brick and paved finishes. You could also use colour to create warmth or an aged look and can create a stamped concrete look.        Are there any restrictions?        Pre-existing coatings should be ground off prior to resurfacing the concrete, as the coatings compatibility could affect the adhesion.        While small cracks can be covered during resurfacing, larger cracks will need to be repaired before any resurfacing is done.  An epoxy and silica sand mix is usually used for repairing small to medium cracks. Whilst repairing cracks there are no guarantees. If the concrete moves and re-cracks then so will your concrete resurfacing. If any structural damage has been done to your concrete, such as underlying soil movement, resurfacing will not solve the problem.        Importantly, always make sure you have a sound foundation for your concrete resurfacing work. As many who have tried to resurface on their own have learned, if the base concrete is dusty, flaky, weak and/or chalky, the coatings might simply lift off. If this is the case, additional preparation needs to be taken to grind the cement laitance off the top so you have a solid foundation to work with.

Terrazzo is all natural, only consisting of ballast (commonly marble) mixed with cement. Polished terrazzo can be found in a number of colors, so if you wish to let your creativity run free – choose a polished terrazzo floor.The HTC-MethodAll over the world hundreds of HTC grinding machines are in use for grinding and polishing of terrazzo. HTC has developed a special method for this type of floor and a remarkable result is achieved thanks to the machines patented grinding head and the unique diamond tools. With the HTC method you increase your efficiency when grinding terrazzo floors substantially.Just as important as effective machines is the working environment. Our grinding machines are developed with ergonomics as a focus and our separators guarantees a dust free environment.Wet methodInspect the floors regarding how even the slabs are, if there has not been a final grinding performed at construction. With small differences (up to approximately 1 mm) in between individual slabs, a normal CA-series tool could be used. However, with an uneven floor, there is a risk of chipping and a plastic ring tool (segments embedded in a solid plastic ring) should therefore be used instead, for the first stages of the grinding. Be very careful and make sure all grooves from the previous stage are eliminated. Clean the floor after every stage to remove all abrasives of the previous coarser type. As a final stage use the MPC with a polishing pad.Dry methodHTC can also give you advice for a dry grinding procedure. This is however a more difficult method not generally applicable, since it is only suitable for specific types of marble.

Preparing the Garage Floor to Receive the CoatingBefore installing any system to your garage floor, it must be clean and free of any debris that may prevent bonding, such as dirt, oil or sealer. Scrub the floor with detergent and a power scrubber. Acid wash with a solution of four parts water to one part acid, then neutralize the surface with a solution of one part ammonia to ten parts water. Work the neutralizer into the surface with a stiff-bristled brush then rinse with a high-powered washer.Pay special attention to cleaning any cracks that may be in the floor, as they must be dealt with prior to installing your garage floor covering. Small working cracks can be filled with a 100% solids epoxy paste then scraped level with the floor. If the crack is large, overfill it with the epoxy, then grind the epoxy to floor level after it's dry. Stokes recommends using 100% solids epoxy or fast-drying cementitious material to fill in any deteriorated spots or rough areas. For tooled control joints, Stokes suggests applying a thin bead of simple latex caulk to seal the bottom of the joint. This will provide a smooth joint for your garage floor system, resulting in an easy to clean floor. For saw cut or expansion joints, he recommends filling them with a polyurethane caulk.If you suspect your garage floor has moisture issues that will prevent your new flooring system from bonding, there is a simple test you can do. Cut out a square piece of plastic sheeting, approximately 2 ft. by 2 ft., and tape all edges of the sheeting to your floor. If water collects on the underside of the plastic, you have moisture vapor transmission. A good vapor barrier will need to be put down before the primer coat. Discuss this option with your installer.A good garage floor system will consist of a primer, a base coat and a top coat. A primer coat is necessary to ensure a good bond. Apply the primer with a roller according to manufacturer's directions and allow to dry. When the surface is dry to the touch, apply the epoxy or urethane base coat. Broadcast the color flakes evenly into the wet base. The flakes can be applied lightly to show the base color or heavily for increased coverage and durability. Blow or sweep off loose flakes. Scrape the floor using a metal floor scraper to ensure no paint chips are sticking up then blow the floor again. Next seal the system with a finish coat. Stokes recommends a two-part aliphatic polyurethane, which he says is preferable to simple epoxy coatings. "They're the Cadillac of systems," said Stokes. "They are UV resistant, so they won't yellow or fade in the sunlight like epoxies do." Allow floor to dry for 48 hours before allowing foot traffic and up to five days for vehicle traffic. Two sealer coats may be required if a full broadcast is applied.

by Allan StainesAn old concrete floor that is essentially sound but in shabby condition, can be rejuvenated. Here are a few tips...Firstly, check for cracking. Large cracks are indicative of serious problems such as ground movement, insufficient reinforcement or damage by heavy trucks or similar. This situation may require serious remedial attention. Hairline cracks are mainly cosmetic - all floors have them.Hire a water pressure cleaner to give the floor a good scouring. (Be sure to wear protective footwear to prevent injury). Avoid holding the powerful water jet too close. It could strip a trowelled surface in the concrete.Alternatively, apply liquid chlorine across the surface, wait 20 minutes then scrub off thoroughly with a stiff broom and hose (always read instructions on proper use carefully). If chlorinated runoff flows onto gardens, it will damage your plants, so be careful and if this happens, rinse thoroughly (within your own water restriction guidelines where applicable).If the floor is indoors, stand protective covers or sheeting around the walls to prevent moisture penetration. If the floor is stained, apply a coat of diluted hydrochloric acid (dilute one part acid to six to ten parts of water in a plastic bucket). Place the acid into the water. Wear protective goggles and clothing, and always read the safety instructions before using any hazardous materials such as acid). After coating, wait until the reaction has ceased then clean off thoroughly with your hose.Rust stains, with or without cracking often indicates that reinforcing steel placed in the concrete at time of pouring has not been sufficiently embedded and is being affected by the weather. The crack could be increased in width then filled with something like Sikadur-52. Alternatively, if the patch is constantly damp, there could be a water leak under the concrete. This may need to be checked out further.Oil stains can be a major problem when rejuvenating old concrete floors. For light oil stains, you will find that hydrochloric acid usually solves the problem. Again, use as described above, be very careful and follow all safety instructions before use.For heavy oil and grease patches, use the acid treatment a few times. Old oil stains tend to continue to rise to the surface. As an alternative, you could try steam blasting the stains.It may be worthwhile scabbling the surface with a kanga hammer and resurfacing the area with a product such as Ardex K15. On outdoor concrete, you could use Ardex K200. Follow the labeled instructions carefully. You will need to acid clean the raw surface first, followed by a prime coat of Ardex 51.Painting ConcreteSome good preparations are available for painting concrete, and for a great finish you have the choice of gloss or non-slip paints. The non-slip is obviously very practical, whereas gloss is easier to clean, but when wet can be quite slippery. You can always apply a non-slip preparation available from some tile shops.Before you start, allow the concrete to become bone dry then apply the paint with a long-handled paint roller. Apply two or three coats for a deep lustre.Paving ConcreteThe existing concrete may provide an ideal base to receive pavers. If using on a path or driveway, the overall height above grass or ground level will be increased - bear this in mind before starting. If needed, ramp up the surrounding soil to overcome any problem here.On driveways, check if the extra height will still allow at least a 15mm step up to the garage floor. This is to keep water out of your garage under normal wet conditions.Finally: you can Tile itPatios can gain a new zest when updated with stylish tiles. Be aware that you may have to lay a wall flashing when abutting timber walls to maintain waterproofing. You may also have to adjust clearances on exterior opening-out doors to accommodate the new floor height. 

Design ideas for outdoor rooms with fireplaces Nothing does a better job of anchoring an outdoor living room than an authentic outdoor fireplace. In this article, Garden Artisan Scott Cohen shares design and construction insights from over 20 years of high-end residential experience.Outdoor fireplaces continue to grow in popularity with the outdoor room boom fueling the fire. Magazines and web-publishers frequently post beautiful photos of large stone fireplaces and homeowners are now demanding fire places, not just fire pits in their outdoor living rooms.There is a certain romantic ambiance that surrounds an outdoor fireplace. The glow of the flickering flame invites guests to sit down, relax and enjoy life. Properly designed fire features encourage conversation and sooth the soul. Design and installation of these popular features can be lucrative, but be sure to educate yourself on the proper construction techniques beforehand to avoid costly mistakes.

Learn how to use acid-based chemical stains to impart rich, earth-toned color to plain concrete floors Staining imparts a luxurious richness that can't be achieved by any other coloring medium. Rather than produce a solid, opaque effect like paint, stains permeate the concrete to infuse it with luminous, translucent tones that vary depending on the surface they are applied to and the application techniques used. The results can mimic everything from polished marble to tanned leather to natural stone or even stained wood.Stains for concrete come in two general categories: acid-based chemical stains and water-based acrylics. Most acid stains are a mixture of water, hydrochloric acid and acid-soluble metallic salts. They work by penetrating the surface and reacting chemically with the hydrated lime (calcium hydroxide) in the concrete. The acid in the stain lightly etches the surface, allowing the metallic salts to penetrate more easily. Once the stain reacts, it becomes a permanent part of the concrete and won't fade, chip off or peel away. The palette for acid-etch staining is generally limited to earthy tones, such as tans, browns, terra cottas and soft blue-greens.If you want to go beyond the subtle drama and subdued earth-toned palette of acid staining, consider using water-based stains, which come in a much broader spectrum of hues. Most manufacturers offer dozens of standard colors, including black and white and even metallic tints. Like acid stains, water-based stains (typically a blend of acrylic polymers and pigments) penetrate the concrete to produce permanent color, ranging from translucent to opaque depending on the product.Both types of stain can be applied to new or old and plain or integrally colored concrete. They are especially effective for revitalizing dull, lackluster surfaces. Because they penetrate the concrete surface, most stains have excellent UV stability and wear resistance, permitting their use on interior or exterior concrete. Applications range from walkways and patios to family room floors and kitchen countertops. They can also be applied to vertical surfaces such as walls or fireplace surrounds.Like stains for wood, concrete stains are semi-transparent and are intended to enhance rather than disguise the surface. They will not hide cracks, blemishes or other flaws in existing concrete. Nor will they completely mask an underlying color or conceal the texture of the surface. An existing concrete slab with major cracks or spalling is usually not a good candidate for staining because any patchwork is likely to show right through the stain.Because stains must be able to soak into the concrete to achieve full color saturation, they shouldn't be applied to surfaces covered by anything that can inhibit stain penetration, such as dirt, grease, glues, coatings, curing membranes and sealers.

Design versatility, durability and easy maintenance make concrete pavers a good choice for a drivewayBenefitsConcrete pavers are one of your best choices for a new or replacement driveway if your goals are design versatility, durability and easy maintenance. They are comparable to stamped concrete in terms of design options and durability, with the added advantage of easy, seamless replacement if repairs are ever necessary. A paver driveway can also be driven on immediately after installation, unlike poured-in-place concrete. Concrete pavers come in a wide array of colors, shapes and sizes, permitting you to create design schemes that complement your home’s architecture. What’s more, you can mix and match paver patterns and colors to create striking accent borders and medallions.“The cost of installing pavers tends to be higher than stamped and colored concrete. However, the long-term value of pavers is realized in their variety of design and color, ease of spot replacement or repair, and resistance to cracking,” says Brian Ramirez owner of BR Landscapers of East Bay, Tracy, Calif.When installed properly over a well-compacted subbase, pavers will not crack, shift or settle under normal vehicle traffic. Ramirez says that a paver driveway will pay for itself over time, both in lower maintenance costs and longevity. “It will last for decades,” he says. “The bed of aggregate beneath the driveway is strong yet flexible. In addition, the joints between the concrete pavers provide the best of both worlds: strength and flexibility. These driveways will not crack due to freezing or thawing.”MaintenancePaver driveways require minimum maintenance if they are protected with a good sealer and the joints are filled with a polymer sand, which contains a special polymeric additive that binds and hardens the sand and helps to prevent erosion. “If joints are filled with polymer sand at original installation, the need to refill joint sand in 2 to 3 years is usually eliminated,” says Ramirez. “For the best appearance, you should reapply a sealer every few years.”To regularly maintain a paver driveway, remove dirt and leaves by sweeping and occasional rinsing. For heavy oil or grease stains, use a pressure washer with an appropriate cleaning solution. Concrete pavers may settle in spots over time if they aren’t installed properly. However, they can easily be reset with no noticeable patchwork. Simply remove the affected pavers, regrade and recompact the subbase, and reinstall the pavers.In the winter, paver driveways can be plowed or shoveled without dislodgement because they typically have chamfered edges and joints. However, don’t use sharp objects to chop ice, which can damage the pavers. Instead, add traction with sand or apply a noncorrosive deicer, such as calcium magnesium acetate. Avoid the use of sodium chloride (rock salt) and calcium chloride, which can harm the pavers and cause efflorescence.

Want to permanently cover up surface imperfections in existing concrete? Or turn a plain-jane slab from drab to fab? With today's decorative overlays, it's easy to give almost any concrete surface, indoors or out, a complete face-lift and at a much lower cost than removal and replacement. The real challenge is choosing from among the many resurfacing products available and the diverse array of decorative finishes possible. There are multiple options available for achieving any look imaginable with a concrete overlay.Here's a primer of the various overlay types available and the decorative options with each. We also give you pointers on how to choose the best system for a particular application. With the many options available, you're sure to find at least one system that meets your requirements for durability, appearance, maintenance, and cost.Although cement-based overlays have been around for decades, many of today's systems blend polymer resins with cement, sand, and other additives to improve performance, wear resistance, and aesthetic qualities. Polymer-modified overlays can be applied in layers as thin as a credit card or up to several inches thick without delamination or failure. They adhere well to existing concrete and resist damage from salt, chemicals, UV exposure, freeze-thaw conditions, and abrasion.While most types of polymer-modified overlays offer similar performance benefits, each system has its own unique characteristics. Overlay manufacturers use different types of polymer resins, often blending them to produce proprietary products with distinct physical attributes. Many of today's decorative overlays use acrylics or acrylic blends because these resins provide excellent bond strength and UV resistance.Before you read any further, though, it's important to be aware that not all existing concrete can be resurfaced. The underlying base for an overlay must be sound. If your concrete is heaving, has severe cracks, is spalling due to damage from deicing salts and freeze-thaw cycles, or resting on unstable soil, resurfacing will not solve your problems. This is when total replacement will be your best option. 

BenefitsConcrete pavers are a great option for pool decks because they are durable, slip resistant and can provide the look of natural stone. “They have many qualities that make them the perfect choice for pool deck paving applications,” says Brian Ramirez, owner of BR Landscapers of East Bay, Tracy, Calif. “They are salt resistant, slip resistant, and chlorine will not affect their colors. Around pools, the joints will take on moisture and leave the pavement cooler underfoot.”Nick Hanna of NRC Landscape Construction, Vienna, Va., says that his customers like pool-deck pavers because they are foot-friendly and provide good traction. “Pavers come in many different textures. Some pavers have dimples in them, and customers say they feel soft on bare feet. Most pavers also surpass ADA guidelines for traction,” he says.Concrete pavers also come in a wide array of colors, shapes and sizes, permitting you to create design schemes that complement your pool’s shape and style. You can also use the pavers to build raised seat walls, pillars or planter boxes that will coordinate with the pool deck itself.Another advantage of using pavers for pool decks is that they can be spot replaced, if necessary. “If there is a problem with plumbing or electrical, you can lift the pavers and perform your repair,” says Hanna. Also, if you want to add on to your pool deck at a later time, it’s easy to install matching pavers and create a seamless transition. One drawback of pavers is the cost, which tends to be higher than stamped and colored concrete. However, they offer great long-term value because of their ease of maintenance and resistance to cracking and settling.MaintenanceBecause factory-made concrete pavers are very dense and nonporous, they resist the growth of algae and mildew in wet pool deck environments, especially if they are protected with a sealer. Ramirez recommends filling the joints between pavers with a polymer sand, which contains a special polymeric additive that binds and hardens the sand and helps to prevent erosion. “If joints are filled with polymer sand at original installation, the need to refill joint sand in 2 to 3 years is usually eliminated,” he says.Typically, the only regular maintenance required for a paver pool deck is sweeping and occasional rinsing to remove dirt and leaves. Concrete pavers may settle in spots over time if they aren’t installed properly over a stable subbase. However, they can easily be reset with no noticeable patchwork. Simply remove the affected pavers, regrade and recompact the subbase, and reinstall the pavers.

Concrete homes are known for their durability and cost-saving features. With ICF construction, homeowners are finding that they can design a concrete home to look just like a wood-frame house, but they garner many other added benefits by choosing to build with concrete.If you firmly believe in the adage that your home is your castle, then why not build a true fortress-one that can withstand nearly any assault Mother Nature can dole out without sacrificing the comfort and design flexibility of a traditional home? In fact, more and more homeowners are doing just that, for reasons ranging from reducing escalating heating and cooling costs to allaying fears of being in the path of another hurricane on the magnitude of Katrina.These savvy homeowners are saying "no" to wood framing and erecting their castles using concrete building systems for the exterior structural walls. In 2005, concrete homes accounted for nearly 18% of all new single-family detached homes, up from 16.3% in 2004, according to the National Association of Home Builders (NAHB) and the Portland Cement Association (PCA). Simply put, one out of every six new houses built in the U.S. are now made of concrete.While some of these homes use traditional concrete wall systems, such as concrete masonry and concrete cast onsite in removable forms, the most explosive growth is in the use of insulating concrete forms, or ICFs, for building both foundation and above-grade walls. These easy-to-erect, stay-in-place forms are made of high-density plastic foam and filled with fresh concrete and steel reinforcement to create a super-insulated thermal sandwich that's airtight, quiet, and highly resistant to fire and strong winds. And ICF walls can be covered with most standard interior and exterior finishing materials, allowing your fortress to assume any architectural style, from Victorian to Colonial to ultra-contemporary.Although it's almost impossible to spot a concrete home, since the walls are often hiding beneath a traditional façade of brick, stucco or lap siding, chances are good that at least one is located right in your own neighborhood. ICF homes are going up in all regions of the country, especially in areas vulnerable to devastating hurricanes and tornadoes and climate extremes. Many of these houses are custom built, but more builders are beginning to erect entire subdivisions of concrete homes.

Concrete pavers, often referred to as paving stones, are a popular outdoor flooring option. Similar to tiles, pavers are manufactured in a factory in specific shapes, sizes and colors and arrive on site ready to be installed. Pavers are most commonly installed over a compacted base of soil and sand. Because there isn’t any grout between the joints, concrete pavers offer a permeable surface that allows water to pass through. However, this also means that they may shift over time and that weeds could grow between the stones. Hiring a professional paver contractor to install your pavers, rather than laying them yourself, is the best way to protect your patio, driveway or sidewalk from these concerns.The use of concrete pavers is growing rapidly on both commercial and residential construction projects. Interlocking pavers form a patterned surface which can be put into service immediately. Pavers are manufactured in various textures and colors. A big benefit of pavers is that they can be removed and re-installed, which reduces future service interruptions.The use of concrete pavers is expanding rapidly. There is plenty of growth to go: in Europe there are 100 square feet of pavers installed per person annually whereas, in the United States it is only 1 square foot per person. Pavers can be installed on your driveway, on a walkway, and on a patio. Pavers come in a variety of patterns, colors and styles to suit most any design idea.

Concrete walkways or sidewalks are more than just a way to get wherever it is you're going—they can provide much-needed curb appeal to homes and buildings, and they are fast becoming a point of artistic expression by way of a multitude of decorative concrete options.While plain gray concrete is still the most often surface installed, as seen on most concrete sidewalks, there are numerous decorative concrete alternatives sure to dress it up, taking your sidewalk from boring to amazing.The best part is that most of the options will work just as well on an existing walkway, because the concrete industry has rapidly developed many decorative products that can be applied to existing plain concrete walkways.Concrete has become the new material of choice for designers across the U.S. Decorative concrete in all of its stained, colored, molded and personalized glory is popping up in retail stores, trendy restaurants, offices and homes everywhere. Now you can find out why!

For decorative contractors who use concrete as a canvas for color, the combination of chemical stains and concrete dyes is a perfect synergy. Although stains have received much applause for their amazing color transformations, dyes deserve equal kudos. These underrated coloring agents can achieve vibrant tones simply not possible with stains alone."Dyes can get the applicator into more vibrant colors such as yellow, blue, and purple to name a few," says Bob Harris, president of The Decorative Concrete Institute and author of Bob Harris Guide to Stained Concrete Interior Floors. The nice thing about working with dyes is that you can mix them at the jobsite to obtain your desired color. Dyes are often used in conjunction with acid stains to produce a variegated look and, in most cases, complement the already stained floor.Gary Jones of Colormaker Floors Ltd. agrees about the versatility of dyes. His company offers a proprietary line of water- and solvent-based dyes in a vast array of colors, including subtle earth tones, vibrant hues, and pastels. "We use a lot of dyes, which for us go hand-in-hand with the patina stains," he says. "The dyes back up the stain and give you a wider range and vibrancy of color. They also allow you to do more layering of color."Another proponent of dyes is artist Dana Boyer, owner of ConcretiZen. She makes her own dyes to enhance and customize her stained concrete work. "Applying a dye is like putting blush on your cheeks, over a foundation. It bumps up the color a notch," she says. Boyer notes that acid stains generally come in only about eight or so neutral colors. "With dyes, almost any color is achievable. It's an enhancement for the stain," she says. "You start with a base of color and build up from there."Les Davis, from American Decorative Concrete , had this important comment about concrete dyes: Translucent dyes penetrate the concrete drying in less than one minute in most climates with minimal cleaning required following the application. Therefore, the applicator completes the job about 60% faster than a typical acid stain due to reduced dry time and less cleaning. If you protect the surface with a topical sealer and/or wax you get a very vestal floor. Most water-based, solvent-based, or urethane-based sealers are compatible with dyes. In conclusion, dye is a powerful solution in virtually any application when the installer is seeking rich mottling effects with minimal installation time.

Polished concrete is fast becoming the ultimate no-wax flooring material. Thanks to recent advances in polishing equipment and techniques, contractors are now grinding concrete floor surfaces, whether new or old, to a high-gloss finish that never needs waxes or coatings. Factor in the superior durability and performance of concrete, and it's no wonder why more retail, warehouse, and office facilities are opting for polished concrete flooring as an alternative to marble, granite, tile, linoleum, or coated concrete. Even homeowners are catching on to the appeal of these smooth, high-luster floors, which can be stained to replicate the look of polished stone.Because polishing is a multistep process, you can choose the level of sheen -- from satin to high-gloss -- that meets your maintenance and aesthetic requirements. This versatility makes polished concrete an ideal flooring material for a variety of applications.This section offers a complete overview of polished concrete floors, including benefits, design options, equipment requirements and maintenance needs.You'll learn the basic steps in the polishing process, the differences between wet and dry polishing, and the advantages of polished concrete compared with other flooring materials including carpeting, wood, ceramic tile, natural stone, and vinyl tile. You'll also find the average costs of polished concrete and what factors affect the final price of installing polished concrete floors.You'll learn how to prepare concrete surfaces before polishing to ensure good results, as well as why some concrete floors may not be good candidates for polishing. Also discover the difference between the various levels of shine possible with polished concrete, ranging from low gloss to reflective mirror-like finishes.Plus get popular design options for polished concrete, including coloring with stains and dyes, decorative engraving, and stenciled graphics. Find ideas for achieving interesting decorative effects by applying multiple colors of dye and using faux-finishing techniques.Finally, you'll find instructions for cleaning and maintaining polished concrete, how to improve the slip-resistance of polished concrete floors and the environmentally friendly attributes of polished concrete.Be aware that the process of polishing concrete floors requires a great deal of expertise and the use of specialized heavy-duty polishing machines equipped with diamond-impregnated disks that gradually grind down surfaces to the desired degree of shine and smoothness. Considering the investment in equipment and the skill required, it's definitely not a project for the do-it-yourselfer. You'll want to hire a professional concrete polishing contractor to do the work.Factor in the superior durability and performance of concrete, and it's no wonder why more retail, warehouse, and office facilities are opting for polished concrete flooring as an alternative to marble, granite, tile, linoleum, or coated concrete. Even homeowners are catching on to the appeal of these smooth, high-luster floors, which can be stained to replicate the look of polished stone.

Staining imparts a luxurious richness that can't be achieved by any other coloring medium. Rather than produce a solid, opaque effect like paint, stains permeate the concrete to infuse it with luminous, translucent tones that vary depending on the surface they are applied to and the application techniques used. The results can mimic everything from polished marble to tanned leather to natural stone or even stained wood.Stains for concrete come in two general categories: acid-based chemical stains and water-based acrylics. Most acid stains are a mixture of water, hydrochloric acid and acid-soluble metallic salts. They work by penetrating the surface and reacting chemically with the hydrated lime (calcium hydroxide) in the concrete. The acid in the stain lightly etches the surface, allowing the metallic salts to penetrate more easily. Once the stain reacts, it becomes a permanent part of the concrete and won't fade, chip off or peel away. The palette for acid-etch staining is generally limited to earthy tones, such as tans, browns, terra cottas and soft blue-greens.If you want to go beyond the subtle drama and subdued earth-toned palette of acid staining, consider using water-based stains, which come in a much broader spectrum of hues. Most manufacturers offer dozens of standard colors, including black and white and even metallic tints. Like acid stains, water-based stains (typically a blend of acrylic polymers and pigments) penetrate the concrete to produce permanent color, ranging from translucent to opaque depending on the product.Both types of stain can be applied to new or old and plain or integrally colored concrete. They are especially effective for revitalizing dull, lackluster surfaces. Because they penetrate the concrete surface, most stains have excellent UV stability and wear resistance, permitting their use on interior or exterior concrete. Applications range from walkways and patios to family room floors and kitchen countertops. They can also be applied to vertical surfaces such as walls or fireplace surrounds.Like stains for wood, concrete stains are semi-transparent and are intended to enhance rather than disguise the surface. They will not hide cracks, blemishes or other flaws in existing concrete. Nor will they completely mask an underlying color or conceal the texture of the surface. An existing concrete slab with major cracks or spalling is usually not a good candidate for staining because any patchwork is likely to show right through the stain.Because stains must be able to soak into the concrete to achieve full color saturation, they shouldn't be applied to surfaces covered by anything that can inhibit stain penetration, such as dirt, grease, glues, coatings, curing membranes and sealers.

Stamped concrete, often called textured or imprinted concrete, is concrete that replicates stones such as slate and flagstone, tile, brick and even wood. Ideal for beautifying pool decks, driveways, entries, courtyards, and patios, stamped concrete is the perfect outdoor paving choice.Recently, stamped concrete has become a popular choice for many homeowners because it offers a wide array of options when it comes to concrete pattern and concrete colors. Another factor contributing to its popularity is its price. The cost of stamped or imprinted concrete is often considerably lower than the materials it is a substitute for.Concrete is the perfect canvas for creating a cost-effective replica of more expensive materials, without giving up a natural, authentic look. When choosing colors and patterns for your stamped cement, make sure they blend with other stone, tile or textured concrete elements at your residence. Even in complex designs with steps and fountains, patterns can be still be pressed into the concrete. Stamped concrete can also be used in conjunction with other decorative concrete elements such as exposed aggregate or acid staining. Popular patterns include running bond brick, hexagonal tile, worn rock or stone.

Concrete has become the new flooring material of choice for designers and homeowners across the United States. Concrete floors are popping up in retail stores, trendy restaurants, offices, and homes everywhere. Whether it's acid-stained, painted, overlays, microtoppings, radiant floors, or a unique personal floor, concrete floors offer a range unlike any other material. Concrete flooring, sometimes referred to as cement flooring, no longer has to be gray and boring. Now coloring concrete or applying textures, patterns, saw cuts, etc., can bring new life to this traditional substrate.One of the major benefits of concrete floors is their affordability compared to other flooring options. Installing a decorative concrete floor can be quite cost-effective, particularly if you already have a concrete slab that’s ready for staining, polishing or application of a coating or overlay. A basic concrete floor will carry a comparable price tag to linoleum, vinyl, ceramic tile or carpet. While a more complex concrete floor design will run you about the same or slightly less than marble, granite, slate, or high-end wood. Furthermore, the lifetime cost of a concrete floor is very low because they require little upkeep and last for years.A second thing that attracts business and homeowners to concrete flooring is its ease of maintenance. When properly sealed concrete floors can be cleaned with a quick pass of a dust mop. For an occasional deep clean a neutral cleaner and water can be used. The frequency of maintenance is dependent on the amount of traffic the floor receives. Restaurants and businesses with considerable foot traffic may want to use a sacrificial floor wax in addition to a sealer to further protect from abrasion.Finally, people are drawn to concrete floors because of their wide color palette. Stained concrete is an incredibly popular choice for interior floors because of its warm, earthy tones. Concrete can be so naturally colored that it blends seamlessly with other elements in a room - oftentimes, you don't even realize it's a concrete floor you're standing on! While stains are the most common, other coloring options for concrete flooring includes painting, dying and the application of tinted sealers. Check with a professional decorative concrete installer to find out which is best for your circumstances.

Staining imparts a luxurious richness that can't be achieved by any other coloring medium. Rather than produce a solid, opaque effect like paint, stains permeate the concrete to infuse it with luminous, translucent tones that vary depending on the surface they are applied to and the application techniques used. The results can mimic everything from polished marble to tanned leather to natural stone or even stained wood.Stains for concrete come in two general categories: acid-based chemical stains and water-based acrylics. Most acid stains are a mixture of water, hydrochloric acid and acid-soluble metallic salts. They work by penetrating the surface and reacting chemically with the hydrated lime (calcium hydroxide) in the concrete. The acid in the stain lightly etches the surface, allowing the metallic salts to penetrate more easily. Once the stain reacts, it becomes a permanent part of the concrete and won't fade, chip off or peel away. The palette for acid-etch staining is generally limited to earthy tones, such as tans, browns, terra cottas and soft blue-greens.If you want to go beyond the subtle drama and subdued earth-toned palette of acid staining, consider using water-based stains, which come in a much broader spectrum of hues. Most manufacturers offer dozens of standard colors, including black and white and even metallic tints. Like acid stains, water-based stains (typically a blend of acrylic polymers and pigments) penetrate the concrete to produce permanent color, ranging from translucent to opaque depending on the product.Both types of stain can be applied to new or old and plain or integrally colored concrete. They are especially effective for revitalizing dull, lackluster surfaces. Because they penetrate the concrete surface, most stains have excellent UV stability and wear resistance, permitting their use on interior or exterior concrete. Applications range from walkways and patios to family room floors and kitchen countertops. They can also be applied to vertical surfaces such as walls or fireplace surrounds.Like stains for wood, concrete stains are semi-transparent and are intended to enhance rather than disguise the surface. They will not hide cracks, blemishes or other flaws in existing concrete. Nor will they completely mask an underlying color or conceal the texture of the surface. An existing concrete slab with major cracks or spalling is usually not a good candidate for staining because any patchwork is likely to show right through the stain.Because stains must be able to soak into the concrete to achieve full color saturation, they shouldn't be applied to surfaces covered by anything that can inhibit stain penetration, such as dirt, grease, glues, coatings, curing membranes and sealers.

Cracked concrete should be replaced if due to the three conditions listed below:Widespread, deep cracks, settlement has occurredSunken ConcreteFrost HeaveAny patching compound used to patch these types of cracks will only be a short term fix. You definitely would not want to patch these cracks and then spend money resurfacing the concrete or doing a decorative topping.Widespread, deep cracks, settlement has occurredWhen concrete is cracked all the way through the surface due to the weight of large trucks, improper preparation of sub grade, erosion of sub grade, or any other reason:Get the advice of a local soils engineer on sub grade preparation for your area and material needed to prepare sub grade (sometimes existing material is ok)· Remove the concrete· Remove the sub grade· Replace sub grade with compactable material (sometimes existing material is ok)· Compact the sub grade· Pour back concreteSunken ConcreteSunken concrete occurs when the sub grade was not prepared properly. Loose dirt may have been used for the sub grade. When this dirt settles-sometimes due to sprinkler or rain water going under the concrete- the concrete is unsupported and will be more susceptible to sinking.It is possible that the sub grade was compacted and the concrete was subjected to extreme weight which caused the concrete to sink. This can often we fixed with special equipment that raises the concrete without damaging the slab (HMI Concrete Lifting & Raising Equipment).Get the advice of a local soils engineer on sub grade preparation for your area and material needed to prepare sub grade (sometimes existing material is ok)· Remove the concrete· Remove the sub grade· Replace sub grade with compactable material (sometimes existing material is ok)· Compact the sub grade· Pour back concreteFrost HeaveFrost heave is very common in cold climates. Moisture in the ground freezes and the concrete pushes upward.Get the advice of a local soils engineer on sub grade preparation for your area and material needed to prepare sub grade (sometimes existing material is ok)· Remove the concrete· Remove the sub grade· Replace sub grade with compactable material (sometimes existing material is ok)· Compact the sub grade· Pour back concrete

Stampable overlays, or thick-section toppings, are the one decorative overlay market that is not experiencing rapid growth. A combination of economic pressure and technical demand has contributed to the slow decline. “The price point of stamped concrete has caught up [to stamped overlays],” says Trevor Foster, western sales manager with Miracote Products. Over the last decade, stamped concrete has seen a slow decline in price and an overall increase in quality. This trend has negatively affected the stamped overlay market. In many instances, it has become more cost-effective to rip out and replace a concrete slab with stamped concrete than to apply a stampable overlay.Stampable overlays also require a high degree of technical expertise to install, more so than any other decorative overlay. Because of the thicker build (1/4 inch to ½ inch), they require more attention to detail in regard to surface preparation, application and maintenance. Stamped overlays often require aggressive mechanical surface preparation, along with the use of specialty primers. This costs money and takes time, which in some cases makes the price of installing the overlay prohibitive. The mentality of “just overlay it” that permeated the market in the mid-2000s has really hurt stampable overlays. There were many failures, which to this day negatively affect the overlay industry.However, the news is not all negative. Advances in technology and application techniques have contributed to a better product overall and higher-quality installations with greater durability. The trend in stamped overlays today is the same as with microtoppings -- simple, clean, and natural. Light earth-tone colors, such as tans, light browns, and beiges, are popular as are simple stone patterns using cleaner and lighter textures. Another trend is post coloring, which involves applying a stamped overlay in a neutral color then coming back and lightly highlighting the work to accentuate the texture in a very realistic manner.One company seeing an increase in their stamped overlay business because of the trend toward custom coloring is Decorative Concrete Resurfacing, Ballwin, Mo. “We have been offering custom stampable overlay finishes for a few years, and it now makes up 20% of our business,” says company vice president Lisa O’Hern. While it is popular and a growing part of their business, it does come with some barriers. “We find that cost is an issue. Because of the additional labor and cost involved in creating these high-end finishes, many customers can’t afford it,” she says.The ability to control the final color is a real advantage of stampable overlays, especially with the use of lighter colors, which contribute to U.S. Green Building Council LEED points on green projects. Design flexibility and color control also go a long way to realizing an architect’s or homeowner’s design goals.The latest trend in stamped overlays is to go vertical. Special stampable overlay materials are now available that stay in place on vertical wall surfaces and remain pliable for long periods of time, allowing for custom carving and stamping to replicate the look of natural rock and stone formations. These overlays have become viable alternatives on projects where natural stone cannot be installed because of economics or logistics. Although this new application for stampable overlays is still getting its legs, the quality of work and reception in the marketplace points to a bright future.

If you're unsure of whether to take the concrete splash, many designers and architectural concrete contractors recommend trying it out in the bathroom. Because you're working with a small space and it's not a room that you spend a lot of time in, it's a good test room. And if you plan to sell your house in the near future, you may have fears about a radical remodel. But the bathroom is considered safe—it won't be a deal-breaker like a kitchen or master bathroom. And it's probable that your fears will be unfounded and it will end up being a strong selling point and encourage you or future owners to introduce concrete to other rooms.Wanda Ellerbeck of Grotto Designs says that powder rooms are a popular choice for the initiation into decorative concrete. "Often it begins with one item," she says, "like a sink or bathroom vanity. But before you know it, we tie it all together and it's concrete-based."Top 3 Attributes to Consider for Bathroom Countertops1) Price: The true cost of the countertop is not in the concrete itself, but rather in the artisan's creativity and time. 2) Maintenance: Cleaning a concrete countertop is no more difficult than any other type of surface. 3) Design: No other countertop surface offers customization in color, size, shape, and thickness.

For many admirers of decorative concrete, the best attribute is that each installation is totally unique. Concrete can assume nearly any shape, design, pattern or texture. But the one characteristic that most distinguishes decorative concrete is color (often referred to as colour concrete in Australia and Canada), whether used subtly to blend with nature or boldly to make a dramatic design statement.Frankly, unless you're a purist and prefer concrete in its plain-gray state, there's no reason not to enhance it with color. The number of different products for coloring concrete has never been greater, and many manufacturers offer an extensive palette of shades to choose from for colored concrete . And although you'll pay more for colored concrete, the amazing transformation will be well worth the investment. In the hands of a creative contractor, these coloring mediums permit an endless array of decorative effects, from rustic earth-toned sidewalks and patios that harmonize with the surrounding landscape to vibrant multicolored floors that double as works of art.To help you sort through your options, here's a roundup of the most common methods for coloring concrete and the applications they are best suited for. With the exception of integral color, all of these products can be used on new or existing concrete. However, not all coloring methods are suitable for all exposure conditions or types of projects, and some have limitations in terms of color availability and intensity. But when you choose appropriately, you'll end up with rich, permanent color that will take your concrete from utilitarian to spectacular 

Staining imparts a luxurious richness that can't be achieved by any other coloring medium. Rather than produce a solid, opaque effect like paint, stains permeate the concrete to infuse it with luminous, translucent tones that vary depending on the surface they are applied to and the application techniques used. The results can mimic everything from polished marble to tanned leather to natural stone or even stained wood.Stains for concrete come in two general categories: acid-based chemical stains and water-based acrylics. Most acid stains are a mixture of water, hydrochloric acid and acid-soluble metallic salts. They work by penetrating the surface and reacting chemically with the hydrated lime (calcium hydroxide) in the concrete. The acid in the stain lightly etches the surface, allowing the metallic salts to penetrate more easily. Once the stain reacts, it becomes a permanent part of the concrete and won't fade, chip off or peel away. The palette for acid-etch staining is generally limited to earthy tones, such as tans, browns, terra cottas and soft blue-greens.If you want to go beyond the subtle drama and subdued earth-toned palette of acid staining, consider using water-based stains, which come in a much broader spectrum of hues. Most manufacturers offer dozens of standard colors, including black and white and even metallic tints. Like acid stains, water-based stains (typically a blend of acrylic polymers and pigments) penetrate the concrete to produce permanent color, ranging from translucent to opaque depending on the product.Both types of stain can be applied to new or old and plain or integrally colored concrete. They are especially effective for revitalizing dull, lackluster surfaces. Because they penetrate the concrete surface, most stains have excellent UV stability and wear resistance, permitting their use on interior or exterior concrete. Applications range from walkways and patios to family room floors and kitchen countertops. They can also be applied to vertical surfaces such as walls or fireplace surrounds.Like stains for wood, concrete stains are semi-transparent and are intended to enhance rather than disguise the surface. They will not hide cracks, blemishes or other flaws in existing concrete. Nor will they completely mask an underlying color or conceal the texture of the surface. An existing concrete slab with major cracks or spalling is usually not a good candidate for staining because any patchwork is likely to show right through the stain.Because stains must be able to soak into the concrete to achieve full color saturation, they shouldn't be applied to surfaces covered by anything that can inhibit stain penetration, such as dirt, grease, glues, coatings, curing membranes and sealers.

Want to permanently cover up surface imperfections in existing concrete? Or turn a plain-jane slab from drab to fab? With today's decorative overlays, it's easy to give almost any concrete surface, indoors or out, a complete face-lift and at a much lower cost than removal and replacement. The real challenge is choosing from among the many resurfacing products available and the diverse array of decorative finishes possible. There are multiple options available for achieving any look imaginable with a concrete overlay.Here's a primer of the various overlay types available and the decorative options with each. We also give you pointers on how to choose the best system for a particular application. With the many options available, you're sure to find at least one system that meets your requirements for durability, appearance, maintenance, and cost.Although cement-based overlays have been around for decades, many of today's systems blend polymer resins with cement, sand, and other additives to improve performance, wear resistance, and aesthetic qualities. Polymer-modified overlays can be applied in layers as thin as a credit card or up to several inches thick without delamination or failure. They adhere well to existing concrete and resist damage from salt, chemicals, UV exposure, freeze-thaw conditions, and abrasion.While most types of polymer-modified overlays offer similar performance benefits, each system has its own unique characteristics. Overlay manufacturers use different types of polymer resins, often blending them to produce proprietary products with distinct physical attributes. Many of today's decorative overlays use acrylics or acrylic blends because these resins provide excellent bond strength and UV resistance.Before you read any further, though, it's important to be aware that not all existing concrete can be resurfaced. The underlying base for an overlay must be sound. If your concrete is heaving, has severe cracks, is spalling due to damage from deicing salts and freeze-thaw cycles, or resting on unstable soil, resurfacing will not solve your problems. This is when total replacement will be your best option.

By Anne Balogh, Concrete Network ColumnistHeating your home with a forced-air furnace isn't your only option when you have concrete floors. You can save energy and create a healthier, more comfortable living environment by having the floor itself distribute the heat-from the ground up-via a radiant in-floor heating system.The science behind radiant floor heating is quite simple: Tubes that circulate hot water or electrical heating elements are installed in the concrete slab when it's poured, turning the thermal mass of the concrete into an inconspicuous radiator of warm, even heat. Among the many benefits: Your feet are always toasty warm, the temperature is consistent and easy to control, you won't feel the drafts or hear the noise of blowing air, and no dust or allergens get circulated within your home through air vents. Best of all, you'll typically pay lower utility costs than with a forced-air system, because concrete floor radiant heating consumes less energy to achieve the same level of comfort.What if you have an existing concrete floor? Radiant heating is still an option. Newer ultra-thin electric heating mats are available that can be embedded in thin-set cement or gypsum overlays, allowing retrofitting over existing slabs without significantly raising the floor height. Here is more information about what radiant in-floor heating is, how it works, the benefits of radiant heat and where to find installers.

Concrete has become the new flooring material of choice for designers and homeowners across the United States. Concrete floors are popping up in retail stores, trendy restaurants, offices, and homes everywhere. Whether it's acid-stained, painted, overlays, microtoppings, radiant floors, or a unique personal floor, concrete floors offer a range unlike any other material. Concrete flooring, sometimes referred to as cement flooring, no longer has to be gray and boring. Now coloring concrete or applying textures, patterns, saw cuts, etc., can bring new life to this traditional substrate.One of the major benefits of concrete floors is their affordability compared to other flooring options. Installing a decorative concrete floor can be quite cost-effective, particularly if you already have a concrete slab that’s ready for staining, polishing or application of a coating or overlay. A basic concrete floor will carry a comparable price tag to linoleum, vinyl, ceramic tile or carpet. While a more complex concrete floor design will run you about the same or slightly less than marble, granite, slate, or high-end wood. Furthermore, the lifetime cost of a concrete floor is very low because they require little upkeep and last for years.A second thing that attracts business and homeowners to concrete flooring is its ease of maintenance. When properly sealed concrete floors can be cleaned with a quick pass of a dust mop. For an occasional deep clean a neutral cleaner and water can be used. The frequency of maintenance is dependent on the amount of traffic the floor receives. Restaurants and businesses with considerable foot traffic may want to use a sacrificial floor wax in addition to a sealer to further protect from abrasion.Finally, people are drawn to concrete floors because of their wide color palette. Stained concrete is an incredibly popular choice for interior floors because of its warm, earthy tones. Concrete can be so naturally colored that it blends seamlessly with other elements in a room - oftentimes, you don't even realize it's a concrete floor you're standing on! While stains are the most common, other coloring options for concrete flooring includes painting, dying and the application of tinted sealers. Check with a professional decorative concrete installer to find out which is best for your circumstances.Here are some additional benefits of concrete floors according to Barbara Sargent of Kemiko Concrete Floor Stains:· They enhance the integrity of architect's designs.· They are easy to change, especially if you sell your home; the next owner can place carpet or wood on top of the concrete slab.· They are great in regions with a lot of sand or snow.· They are a good alternative to carpet if you have allergies.

Polished concrete is fast becoming the ultimate no-wax flooring material. Thanks to recent advances in polishing equipment and techniques, contractors are now grinding concrete floor surfaces, whether new or old, to a high-gloss finish that never needs waxes or coatings. Factor in the superior durability and performance of concrete, and it's no wonder why more retail, warehouse, and office facilities are opting for polished concrete flooring as an alternative to marble, granite, tile, linoleum, or coated concrete. Even homeowners are catching on to the appeal of these smooth, high-luster floors, which can be stained to replicate the look of polished stone.Because polishing is a multistep process, you can choose the level of sheen -- from satin to high-gloss -- that meets your maintenance and aesthetic requirements. This versatility makes polished concrete an ideal flooring material for a variety of applications.This section offers a complete overview of polished concrete floors, including benefits, design options, equipment requirements and maintenance needs.You'll learn the basic steps in the polishing process, the differences between wet and dry polishing, and the advantages of polished concrete compared with other flooring materials including carpeting, wood, ceramic tile, natural stone, and vinyl tile. You'll also find the average costs of polished concrete and what factors affect the final price of installing polished concrete floors.You'll learn how to prepare concrete surfaces before polishing to ensure good results, as well as why some concrete floors may not be good candidates for polishing. Also discover the difference between the various levels of shine possible with polished concrete, ranging from low gloss to reflective mirror-like finishes.Plus get popular design options for polished concrete, including coloring with stains and dyes, decorative engraving, and stenciled graphics. Find ideas for achieving interesting decorative effects by applying multiple colors of dye and using faux-finishing techniques.Finally, you'll find instructions for cleaning and maintaining polished concrete, how to improve the slip-resistance of polished concrete floors and the environmentally friendly attributes of polished concrete.Be aware that the process of polishing concrete floors requires a great deal of expertise and the use of specialized heavy-duty polishing machines equipped with diamond-impregnated disks that gradually grind down surfaces to the desired degree of shine and smoothness. Considering the investment in equipment and the skill required, it's definitely not a project for the do-it-yourselfer. You'll want to hire a professional concrete polishing contractor to do the work.Factor in the superior durability and performance of concrete, and it's no wonder why more retail, warehouse, and office facilities are opting for polished concrete flooring as an alternative to marble, granite, tile, linoleum, or coated concrete. Even homeowners are catching on to the appeal of these smooth, high-luster floors, which can be stained to replicate the look of polished stone.

Epoxy terrazzoThis mosaic-like floor topping for concrete substrates goes on at a thickness of only ¼ to 3/8 inch. It is excellent for multi-colored patterns and designs because of the epoxy resin matrix. It can be pigmented, like paint, to achieve an unlimited spectrum of colors. It can also be colored with aggregates, including chips of marble or granite, recycled glass, mother of pearl, and various synthetic materials. Virtually indestructible, epoxy terrazzo is ideal for commercial, industrial, and institutional facilities, especially where durability, longevity, and minimal maintenance are crucial. The color and design versatility of epoxy terrazzo also makes it a popular choice for decorative flooring installations, especially in high-traffic retail facilities. Garage floor coatingsThere are also special epoxy floor coating systems specifically for garage floors, to give them a wear- and chemical-resistant surface. They come in a wide variety of color options, and can be accented with decorative quartz or multicolored chips to provide a look similar to granite or terrazzo. Metallic epoxy coatingsThis new type of epoxy-based system allows you to "guild" your concrete to replicate the look of copper, silver, aged bronze, nickel, and other shimmery patinas. Some of these coatings contain real metallic powders, while others use special reflective pigments. They are especially popular for floors in retail, office, and restaurant settings, where a modern, upscale look is desired. How to InstallEpoxy coatings can be installed over most clean, properly prepared concrete slabs. Most manufacturers recommend applying a primer first to improve the epoxy/concrete bond. Installers mix the two-component epoxy resin with the desired decorative aggregate (if used) and then pour the material onto the slab. The final step is to apply a sealer, which makes the surface more resistant to water, chemicals, oil, grease, acids, and solvents.

You've seen how decorative stamping can add beauty and drama to concrete floors, sidewalks, driveways and other horizontal surfaces. But did you know you can use similar stamping and texturing techniques to enhance vertical surfaces, such as the walls inside your home or business, a fireplace front or an exterior privacy wall?More decorative concrete contractors are literally climbing the walls to demonstrate new vertical applications for their artistry. They are defying gravity with the use of new lightweight cement-based wall overlay materials that can be applied directly over virtually any properly prepared wall surface, including concrete and masonry, wood, cement board, plaster, drywall and even insulating concrete forms (ICFs). These tenacious mixes are formulated to go on thickly without sagging, allowing them to be embellished with deep rock textures, wood-grain patterns, grout joints and many other carved or imprinted designs created with special stamps, texturing skins and sculpting tools. What's more, vertical overlays can be colored and stained to simulate the appearance of natural stone, brick or other wall materials.Hand-carved vertical overlays are one of the newest trends in decorative concrete, according to Nathan Giffin, owner of VerticalArtisans.com, who has turned basements into stone-walled coves and old closets into wine cellars. "The design possibilities are endless," he says.Wayne Sellon of Tajmawall is another contractor specializing in stamped and hand-carved vertical overlays. "My customers like the idea that they are getting something that's one of a kind," he says. "I can beat the price of stick-on rock and provide more variety in the texture and staining process."Stan Pace, owner of FossilCrete, a company that sells tools and materials for vertical resurfacing, says the process is perfect for mainstream use. "It's a monolithic system, it's strong, it can be colored and it's an easy application. There's lots of freedom, and it's like a natural product, only better."

Building homes that are green and environmentally friendly has become the mantra for more and more builders and homeowners, as they discover how easy it can be to attain all the benefits of sustainable construction without sacrificing aesthetics or breaking the budget. In fact, going green often saves money, especially over time, while being kinder to planet Earth.Decorative concrete flooring is a perfect example of this synergy of beauty, sustainability and economy, giving you a durable, low-maintenance floor that will last the life of your home. Concrete floors, when left exposed, conserve resources by functioning both as a foundation slab and finished floor. This eliminates the need for carpeting and other floor coverings that would eventually require replacement. In addition to conserving materials, concrete flooring offers many other environmental benefits, such as contributing to better energy efficiency and improving indoor air quality. The topics listed above are the most compelling reasons to go green with decorative concrete floors.Design VersatilityTypically, interior concrete floor slabs have been hidden under other flooring materials such as carpet, hardwood, vinyl or ceramic tile. But why waste resources and money to add another layer of flooring when you can simply leave the concrete exposed?Decorative techniques such as coloring, staining, stamping, stenciling and polishing give you unlimited design versatility, allowing you to create floors that mimic more traditional materials, such as tile or slate, or custom design a look that's totally unique If you're concerned about the toxicity of the products used to color, stain and seal concrete, you now have more environmentally friendly options than ever before. Although some concrete sealers and coatings are still solvent-based, many products today are available in low-odor, nontoxic versions that won't affect indoor air quality.When properly installed and sealed, a decorative concrete floor should last a lifetime and will never need replacement. Few flooring materials can boast this same longevity. Carpet, tile and even wood floors eventually need replacement, which uses up resources and creates waste disposal problems. If you stick with a neutral color palette for your concrete floor, it will easily accommodate any future changes to your interior décor.Concrete floors also utilize sustainable materials. The predominant raw material for the cement in concrete is limestone, the most abundant mineral on earth. Your ready-mix supplier can also make concrete using waste byproducts, which reduces the consumption of raw materials. Fly ash, slag cement and silica fume, all waste byproducts from power plants, steel mills and other manufacturing facilities, are commonly used as partial cement replacements. Decorative concrete floors can also incorporate recycled products, such as crushed glass, bits of recycled plastic, marble chips, metal shavings and even seashells.Finally, in the highly unlikely event that your concrete floor ever needs to be replaced, the concrete itself can also be recycled at the end of its long service life Another way concrete floors minimize waste: The fresh concrete that goes into a floor slab is manufactured at a local ready-mix plant in the quantities needed for each project. This also saves on the energy required to transport a factory-made product such as tile or carpet from the plant, to the distributor and eventually to your home.Energy EfficiencyBecause of their thermal mass and ability to retain heat, concrete floors are ideal for passive solar home designs. When homes are built to take advantage of solar radiation entering through windows in the winter months, concrete floors will absorb the heat from the direct sunlight and release the stored heat as needed at night to keep rooms warmer. Conversely in the summer and in hot climates, concrete floors shielded from the sun will stay cool longer and can actually help lower air-conditioning costs.Concrete floors are also ideal for use with energy-efficient radiant in-floor heating systems. With radiant heating, coils heated by electricity or hot water are embedded in concrete floors, warming the floor itself to deliver clean, even heat. The Healthy House Institute says that with radiant heating, people can be comfortable at lower temperatures than with forced-air heating, helping to rein in utility bills. Another benefit: When homes are heated with in-floor radiant heating, no air is being blown around, as with forced-air systems, so no dust or dirt gets recirculated into the air.EconomyAn exposed concrete floor is often an economical alternative to other finish solutions such as hardwood flooring and tile. For new residential construction or commercial projects with site-cast concrete floor slabs, choosing to leave the concrete floors exposed can save big money over the life of the building. First, you don't have to buy and install an additional floor covering to put on top of the floor slab. In addition, the durability and low maintenance needs of concrete flooring will save you the recurring maintenance and replacement costs associated with less-enduring flooring materials, such as carpet and vinyl tile. In a typical home environment, decorative concrete floors are very low-maintenance, requiring only periodic sweeping or wet mopping 

Concrete has become the new flooring material of choice for designers and homeowners across the United States. Concrete floors are popping up in retail stores, trendy restaurants, offices, and homes everywhere. Whether it's acid-stained, painted, overlays, microtoppings, radiant floors, or a unique personal floor, concrete floors offer a range unlike any other material. Concrete flooring, sometimes referred to as cement flooring, no longer has to be gray and boring. Now coloring concrete or applying textures, patterns, saw cuts, etc., can bring new life to this traditional substrate.One of the major benefits of concrete floors is their affordability compared to other flooring options. Installing a decorative concrete floor can be quite cost-effective, particularly if you already have a concrete slab that’s ready for staining, polishing or application of a coating or overlay. A basic concrete floor will carry a comparable price tag to linoleum, vinyl, ceramic tile or carpet. While a more complex concrete floor design will run you about the same or slightly less than marble, granite, slate, or high-end wood. Furthermore, the lifetime cost of a concrete floor is very low because they require little upkeep and last for years.A second thing that attracts business and homeowners to concrete flooring is its ease of maintenance. When properly sealed concrete floors can be cleaned with a quick pass of a dust mop. For an occasional deep clean a neutral cleaner and water can be used. The frequency of maintenance is dependent on the amount of traffic the floor receives. Restaurants and businesses with considerable foot traffic may want to use a sacrificial floor wax in addition to a sealer to further protect from abrasion.Finally, people are drawn to concrete floors because of their wide color palette. Stained concrete is an incredibly popular choice for interior floors because of its warm, earthy tones. Concrete can be so naturally colored that it blends seamlessly with other elements in a room - oftentimes, you don't even realize it's a concrete floor you're standing on! While stains are the most common, other coloring options for concrete flooring includes painting, dying and the application of tinted sealers. Check with a professional decorative concrete installer to find out which is best for your circumstances.Here are some additional benefits of concrete floors according to Barbara Sargent of Kemiko Concrete Floor Stains:· They enhance the integrity of architect's designs.· They are easy to change, especially if you sell your home; the next owner can place carpet or wood on top of the concrete slab.· They are great in regions with a lot of sand or snow.· They are a good alternative to carpet if you have allergies.

Staining imparts a luxurious richness that can't be achieved by any other coloring medium. Rather than produce a solid, opaque effect like paint, stains permeate the concrete to infuse it with luminous, translucent tones that vary depending on the surface they are applied to and the application techniques used. The results can mimic everything from polished marble to tanned leather to natural stone or even stained wood.Stains for concrete come in two general categories: acid-based chemical stains and water-based acrylics. Most acid stains are a mixture of water, hydrochloric acid and acid-soluble metallic salts. They work by penetrating the surface and reacting chemically with the hydrated lime (calcium hydroxide) in the concrete. The acid in the stain lightly etches the surface, allowing the metallic salts to penetrate more easily. Once the stain reacts, it becomes a permanent part of the concrete and won't fade, chip off or peel away. The palette for acid-etch staining is generally limited to earthy tones, such as tans, browns, terra cottas and soft blue-greens.If you want to go beyond the subtle drama and subdued earth-toned palette of acid staining, consider using water-based stains, which come in a much broader spectrum of hues. Most manufacturers offer dozens of standard colors, including black and white and even metallic tints. Like acid stains, water-based stains (typically a blend of acrylic polymers and pigments) penetrate the concrete to produce permanent color, ranging from translucent to opaque depending on the product.Both types of stain can be applied to new or old and plain or integrally colored concrete. They are especially effective for revitalizing dull, lackluster surfaces. Because they penetrate the concrete surface, most stains have excellent UV stability and wear resistance, permitting their use on interior or exterior concrete. Applications range from walkways and patios to family room floors and kitchen countertops. They can also be applied to vertical surfaces such as walls or fireplace surrounds.Like stains for wood, concrete stains are semi-transparent and are intended to enhance rather than disguise the surface. They will not hide cracks, blemishes or other flaws in existing concrete. Nor will they completely mask an underlying color or conceal the texture of the surface. An existing concrete slab with major cracks or spalling is usually not a good candidate for staining because any patchwork is likely to show right through the stain.Because stains must be able to soak into the concrete to achieve full color saturation, they shouldn't be applied to surfaces covered by anything that can inhibit stain penetration, such as dirt, grease, glues, coatings, curing membranes and sealers.

Portland Cement is a type of cement, not a brand name. Many cement manufacturers make Portland Cement.To find out more about what concrete is made of, concrete mix designs, admixtures, and water to cement ratiosType 1 - Normal portland cement. Type 1 is a general use cement.Type 2 - Is used for structures in water or soil containing moderate amounts of sulfate, or when heat build-up is a concern.Type 3 - High early strength. Used when high strength are desired at very early periods.Type 4 - Low heat portland cement. Used where the amount and rate of heat generation must be kept to a minimum.Type 5 - Sulfate resistant portland cement. Used where the water or soil is high in alkali.Types IA, IIA and IIIA are cements used to make air-entrained concrete. They have the same properties as types I, II, and III, except that they have small quantities of air-entrained materials combined with them.These are very short descriptions of the basic types of cement. There are other types for various purposes such as architectural concrete and masonry cements, just to name two examples.Your ready mix company will know what the requirements are for your area and for your particular use. Simply ask them what their standard type of cement is and if that will work fine for your conditions.

With colored concrete, the creative options and color choices are endless, making it possible to achieve the perfect look. Colored concrete can transform a room or patio from plain to spectacular. Many manufacturers offer a broad palette of colors to choose from, ranging from earth tones to vibrant hues. Also, colored concrete can be used to simulate the look of brick, flagstone, pavers, or tile. Not only is concrete coloring a beautiful design option, but it is also affordable and compatible with both new and existing concrete. With the right products, techniques, and a creative contractor you can produce results that will transform concrete into works of art.Finishing (Texturing) Techniques for Colored ConcreteColored concrete can be paired with other concrete finishing techniques to create a striking affect. These techniques include broom finishing, sandblasting, exposing of aggregate and more. Broom finishing can create shadow effects, "swirl" and "fan" patterns on colored concrete. Sandblasting can be used to create designs, or to give the concrete a two-tone appearance by removing a layer of color. Exposing of aggregate gives the concrete a natural textured look by letting the stone or gravel in the concrete show through.Using Colored Concrete to Break up Large AreasMultiple colors can be used side-by side to break up large areas. Also, color can be paired with other decorative techniques such asstamping, sawcutting, brooming, or sandblasting to make the look even more personal. Another option for breaking up large areas of colored concrete is insetting materials such as granite, marble, tile or personal items.Colored Concrete to Mimic NatureColor schemes are often chosen to blend with each other and blend with nature. Sometimes concrete is colored and finished to look like a gravel path.Often it is necessary to have the permanence of concrete (and the durability). But where plain concrete's gray color would draw attention to a drainage ditch or path, colored concrete can be used to avoid drawing attention to these features and help those features blend with the other landscape elements.Hiding Future Stains by Using Colored ConcreteMost driveway, parking lots, and other parking areas are light gray concrete and soon become stained with oil and grease, tire marks, and dirt.Many property owners will add a dark integral color to parking area concrete and then expose the aggregate in the concrete by sandblasting (medium to heavy) or by using a surface retarder. Roll curbs can be treated the same way. The lighter salt and pepper grays of the aggregate blend with the dark gray matrix of the cement paste.Grease and oil stains will be much less apparent, lost in the different shades of gray. Tire marks also do not show as bad on exposed aggregate.

Even though concrete patios aren’t exposed to vehicle traffic or deicing salts, like concrete driveways are, they still take plenty of punishment. Backyard barbecues, outdoor campfires, heavy foot traffic, and unrelenting sunshine can cause patios to fade, discolor, and abrade if you leave them unprotected. A good sealer can keep new concrete patios looking great for many years to come and even improve the appearance of existing patios, especially if they are topically colored. If sealing isn’t already a routine part of your concrete patio maintenance plan, here’s what you need to know to get started.Why Is Applying Sealer Important?The reasons for sealing a concrete patio are similar to those for waxing a car, wearing sunscreen, or applying stain repellent to new carpeting. It’s done to enhance the appearance, keep the color from fading due to sun exposure, and protect it from stains and moisture absorption.If your patio is located in a region of the country subject to freeze-thaw cycles, applying sealer will reduce the chance of freeze-thaw damage - the ugly surface spalling and scaling that can occur after water is absorbed into concrete and expands when it freezes. Although concrete patios aren’t typically exposed to deicing salts, which can aggravate the problem, they are still porous and will absorb water if left unsealed.For stamped concrete patios, which are typically enhanced by surface-applied color.  a sealer will help prevent the color from fading over time due to sun exposure, foot traffic, and abrasion. Sealers will also help prevent discoloration caused by common outdoor stains such as dirt, leaves, lawn chemicals, food spills, and residue from fire pits. Many concrete sealers intended for outdoor use contain UV protectants and stain repellents that will virtually eliminate fading and make the concrete easier to clean and maintain.How Do I Choose the Best Sealer for My Patio Project?The primary type of sealer used on decorative concrete patios and other exterior flatwork is a solvent- or water-based acrylic. Acrylic sealers are easy to apply, economical, and well-suited for outdoor use because they are UV resistant, non-yellowing and breathable, which means they provide good water repellence while allowing moisture vapor within the slab to escape. If you don't want a sheen on the patio surface and prefer a natural look, a penetrating sealer is an alternative that provides good protection against outdoor exposure conditions without forming a surface film.The first and most important consideration when choosing a sealer is whether the product is compatible with the decorative concrete patio surface you plan to apply it to. The type of finish you want to achieve (such as matte vs. high gloss) comes in a close second. you should evaluate when choosing a sealer appropriate for your project and budget.

How Do Sealers Improve Patio Appearance?In addition to protecting colored concrete patios from fading, a sealer can also enhance and intensify the color. Depending on the type of sealer you apply, your options range from a natural matte finish to a high-gloss sheen.Chemically reactive sealers are nearly invisible because they penetrate into the concrete, making them great choices for concrete patios that are stamped to replicate weathered stone. Water-based acrylic resin sealers will provide greater color enhancement and a low-gloss satin finish. And solvent-based acrylic sealers and epoxies will give concrete a high-gloss wet look and significantly deepen the color. There are also sealers specifically formulated to enhance the beauty of natural stone in exposed aggregate concrete .Here are several examples of stamped and stained concrete patios that were enhanced by the application of a sealer:Patio Showcases the Beauty of Natural GrayBeautiful ChemistryConcrete Patio Showcases Creative StainingTiered Concrete Patio Mimics Grouted StoneWill a Sealer Make Concrete Patios Slippery?Film-forming, high-gloss sealers can really intensify the color of a concrete patio, but they may also make the surface more slippery, especially when wet. That’s usually not a concern with exposed aggregate or textured concrete patio surfaces, but smooth, untextured concrete may require the use of anti-skid additives to improve the traction. Most of these additives are simply mixed into the sealer at the time of application and are transparent, so they won’t alter the color or appearance . Another option is to switch to a penetrating sealer that won’t form a surface film.Can a Patio Sealer Be Colored?Most clear water- and solvent-based sealers can be tinted, allowing you to add another layer of color to a decorative concrete finish. Some manufacturers offer pre-tinted sealers, while others provide tint concentrates that you can add to the sealer at the jobsite. A tinted sealer can also be used as a stand-alone, low-cost decorative finish if just a hint of color is desired. How Do I Prepare the Surface?The answer to this question often depends on whether you’re applying sealer to a new of existing concrete patio. In order for a sealer to properly adhere to the concrete, the surface must be free of dirt, oil stains, existing coatings, and any other substance that might inhibit sealer penetration. Newly placed concrete patios typically require very little preparation, while existing surfaces may need to be power washed with soap and water and possibly acid etched.The porosity of the concrete is also important and will determine how well the sealer will soak into the surface. If the sealer can't adhere, it won't be long before it peels off and flakes away. Because most patios are hand troweled, they are usually porous enough to accept a low-solids sealer without additional surface profiling. However, if the concrete is very tight or dense, you may need to open up the surface by light sanding or acid etching. For more guidance

When Is the Best Time to Apply Sealer?When you apply a patio sealer is almost as important as good surface preparation in terms of long-term durability and performance. The biggest factors to consider are the age of the concrete, weather conditions, and dry times.New concrete patios should be allowed to cure completely before sealer application (typically at least 28 days). Most sealers also must be applied to dry surfaces. With stamped concrete, it’s especially important to make sure the patio is free of moisture in low spots of the stamp pattern, where water may accumulate. You should monitor the air temperature as well. As a general rule, wait to apply outdoor sealers when the temperature is between 50 to 90 degrees F both during and for at least 24 hours after application so the sealer will cure properly.Also make plans to apply sealer when the patio won’t be in use for a few days. Depending on the product you’re using, dry times for concrete sealers can range from one to three days before the surface can be exposed to a lot of backyard foot traffic.How Is Patio Sealer Applied, and What Tools Do I Need?Many sealers for concrete patios can be applied using simple tools, such as a paint roller or pump-up sprayer. As a general guide, solvent-based sealers are best applied by spray while water-based sealers are best applied by roller. If the patio is textured or stamped, be sure to use a roller with a fairly thick nap so you can work it into the depressions. One of the best application techniques when sealing stamped or textured patios is to combine spraying followed by back rolling to keep the sealer from settling in low spots.Whether you are rolling or spray applying a sealer, always follow the manufacturer’s recommended application guidelines and coverage rates. Often you’ll get better results by applying patio sealer in two thin coats, which will ensure more uniform coverage. If you apply the sealer too thickly, it will just lie or puddle on the surface rather than penetrate.When Is It Time to Reseal a Concrete Patio?Even when properly applied to a clean well-profiled surface, a sealer will wear away over time. The average service life is three to five years, depending on foot traffic, weather, and other exposure conditions. Resealing a concrete patio on a regular basis will help to preserve its color and resilience.There are several ways you can tell when a patio needs a new coat of sealer. Has the surface lost its sheen? Does water soak in rather than bead up on top? Is the finish beginning to show signs of wear? If the answer to all of these questions is yes, it’s time to reseal.Often all you need to do is to give the concrete patio a good soap and water cleaning, followed by a light reapplication of the same sealer used initially. However, if you are switching to a different brand or type of sealer, most manufacturers recommend removing all traces of previously used sealers because the products may not be compatible. Never apply a solvent-based sealer over a water-based product because the solvent can eat away or soften the existing water-based sealer.What If Blisters and Bubbles Form on the Sealer Surface?Blistering or bubbling of a sealer is rare, but it can really detract from the beauty of a decorative concrete patio when it occurs. The problem is usually caused when air or gases are trapped by the sealer during the curing phase, and is more common with solvent-based products. If the sealer dries too rapidly or too slowly or the top dries before the bottom (due to climate conditions or the sealer being applied too thickly), the potential is there to trap gas and create blisters.

Colored and stamped concrete is an ideal pool deck surface, combining the attributes of beauty, durability, and low maintenance. Stamped concrete pool decks give you a vast array of decorative options not possible with other pool deck materials. You can choose from many different stone, brick, and tile patterns and even wood-grained textures. Using stains, powdered pigments and antiquing agents, contractors can color your pool deck to look identical to natural stone or customize the color to complement your home and landscape. When properly sealed, stamped concrete will also resist harsh pool chemicals, constant water exposure, and fading. If you're worried about your pool deck getting slippery when wet, you can easily improve the traction by mixing a nonskid grit additive into the sealer. Here are some other ideas for enhancing the look and function of a stamped concrete pool deck:Design ideas:· If your concrete pool deck is exposed to the hot sun all day, you can keep the surface cooler by coloring the concrete with lighter shades, such as sand, coral or pearly white tones.· Avoid using stamp patterns with deep grout lines or rough surface textures, which can allow water to collect and be uncomfortable to walk on in bare feet.· Set off your pool deck and add decorative interest by installing a pool border, or coping, in a contrasting color and pattern. Options include broom-finished concrete, limestone, concrete tile, and hand-scored concrete.· Terrace the levels of your stamped concrete pool deck to provide separate zones for lounging and recreation.

One of the most important considerations for any pool deck is the type of material to use. The material you ultimately choose often depends on a number of factors including your surrounding landscape, space availability, how much traffic the pool deck will receive, budget, and how much time and effort you want to devote to care and upkeep. Concrete, more than any other material, will allow you to design a truly unique, affordable and low-maintenance pool deck that becomes the social hub and aesthetic focal point of your backyard.Only decorative concrete gives you the ability to select any shape, size, color and surface treatment for your deck—from plain broom-finished concrete, to exposed aggregate, to imprinted patterns that mimic tile, brick or natural stone. You can also mix and match decorative treatments, such as combining stained concrete with a stenciled or imprinted border or enhancing a colored overlay with sawcut or engraved patternsFlagstone, sometimes known as "bluestone," offers a sleek and traditional look. However, very sunny sites will often heat flagstone to uncomfortable levels, particularly for young children. While many different colors and patterns are available with brick decks, brick, too, can be a hot, sometimes slippery surface.Many design combinations, such as that of brick pavers, flagstone coping and border bands can be taken into consideration. In climates where freezing occurs, "antique" brick are to be avoided as this material is known to absorb water and spall or crack during the frozen winter months. Granite decks offer the rustic look of stone and great durability.

To ensure that your concrete driveway will look good for many years to come, there are important steps your contractor should follow during installation. How well your driveway looks and performs long-term is largely related to the quality of workmanship and materials that go into it. To help ensure a problem-free driveway, use the following links for information about proper construction.A properly prepared subgradeUniformity, in both soil composition and compaction, is the key to a good subgrade-one that will provide adequate support, ensure an even slab thickness, and prevent slab settlement and structural cracking. Soft spots should be removed and replaced with good material, such as gravel or crushed rock. Many western states have expansive soils. In these conditions, 2 to 8 inches of crushed rock should be used as subgrade material, depending on the degree of expansiveness. If you are unsure about the soil characteristics in your area, consult a soils engineer.Don't allow the concrete to be placed on bone-dry subgrade, advises the Tennessee Concrete Association. Spraying the subgrade first to dampen it will prevent it from wicking water from the fresh concrete.Vibratory plate compactors and rammers are the most common machines used for subgrade compaction of residential driveways. Click here to read more about subgrades and subbases for concrete slabs.The correct concrete mixMix design will impact the performance and longevity of a concrete driveway. Read more about concrete driveway mix design to find out exactly what to ask for.Correctly placed jointsTo help prevent random cracking, control joints should be placed at a maximum spacing of 10 feet for a 4-inch-thick driveway slab. While random cracks are generally not a structural problem and will not reduce the service life of the driveway, they can be an eyesore. Also avoid joint patterns that produce rectangular or triangular sections. The depth of control joints is also critical. Your concrete installer should hand tool or sawcut them to a depth equaling one-fourth the slab thickness (or 1 inch for a 4-inch slab).In addition to control joints, an isolation joint should be installed where the driveway meets a sidewalk, garage floor slab, and other existing pavements. Ask your contractor to provide a jointing plan as part of his written proposal.ReinforcementUsing steel reinforcement will provide additional structural capacity for your driveway and is especially important if the slab will be exposed to heavy traffic. Reinforcement won't prevent cracks, but it will help hold them together if they do occur. Reinforcement can be either wire mesh or ½-inch (#4) steel rebar placed in a grid pattern with a spacing between bars of approximately 12 inches. In either case, blocks should be used under the reinforcement to keep centered within the concrete.Synthetic fibers have also proven to be beneficial in driveways as a way to reduce shrinkage cracks. Fibers will not provide structural reinforcement, however. Placing concrete at the proper thicknessThickness is the major factor (even more than the strength of the concrete) in determining a driveway's structural capacity. Place concrete at a minimum thickness of 4 inches. Increasing the thickness from 4 inches to 5 inches will add approximately 20% to your concrete cost, but will also boost your driveway's load-carrying capacity nearly 50% , according to the Tennessee Concrete Association. Also consider thickening the edges of the driveway by 1 or 2 inches to provide additional structural support in the area most likely to be subject to heavy loading, with the thickened section extending in from the slab edge 4 to 8 inches.Proper finishingThe biggest mistakes that occur during the finishing of concrete driveways are overworking the surface and performing finishing operations while bleedwater is present.Finishing is generally a three-step process. Your contractor should:· Level or strike off the concrete with a screed to achieve a uniform surface.· Float the concrete with a wood or magnesium bullfloat before bleedwater accumulates.· Apply a simple broom finish to improve traction-unless plans call for stamping the driveway or applying another type of decorative textured finishFinal finishing with a steel trowel is unnecessary and can actually do more harm than good by sealing the concrete surface prematurely and preventing the evaporation of bleedwater.Read about proper finishing tools.Proper drainageTo eliminate standing water on your driveway, it should be sloped toward the street and away from existing structures (such as your house and garage) a minimum of 1/8 inch per foot, recommends the Portland Cement Association. If proper drainage is prevented because the concrete slab is wedged between two structures, you may need to install a drain that will collect the water at a low point in the concrete and divert it away.Proper curing techniquesCure the concrete as soon as finishing is completed. Curing of the concrete is the final step of the process, and one of the most important. Unfortunately, it's also one of the most neglected. In extreme cases, failure to cure the concrete immediately after final finishing can result in strength reductions of up to 50% by reducing the concrete's resistance to the effects of weather and increasing the possibility of surface defects.Methods of curing include covering the concrete with plastic sheets or wet curing blankets, continuous sprinkling, and application of a liquid membrane-forming curing compound. For slabs that are to be acid stained, wet curing is the best approach, since a curing compound would have to be completely removed to allow the acid stain to penetrate. The most common way to cure plain or integrally colored concrete, though, is to use a liquid curing compound. Read more about why curing concrete is important and how it's done.

By Bill Palmer, ConcreteNetwork.com ColumnistA perpetual problem with thin overlays is that since they form an impermeable layer on the slab, any water vapor emissions from the underlying slab will be trapped. This vapor can then develop more pressure than the bond strength between the topping and the slab, delaminating the topping. Slabs that lack under-slab vapor barriers will nearly always have some water vapor emission from water below the slab, and newer slabs, even with vapor barriers, will need time to dry out. Overlay manufacturers typically recommend a moisture vapor emissions rate (MVER) of 3 pounds per 1000 square feet in 24 hours Dave Pettigrew of Diamond D Concrete, Capitola, Calif. has developed what he says is sure-fire way to overcome this problem. He uses this method on "any floor I suspect might have vapor emissions and on anything over 20 years old," since older floors seldom had quality vapor barriers. "Anytime there's no vapor barrier you're going to get vapor emissions and that's the beast we all have to deal with—trying to get those vapors blocked. For years I listened to various manufacturers and they all said they had a way, but I was the one who had to go back and repair the floors when they came up."So Pettigrew took a lesson from the epoxy floor industry. "I realized that the epoxy people had been bonding to concrete way back in the 1940s and 50s before we even had vapor barriers and I thought that if they could get it to bond then I could get it to bond."From Crown Polymers he purchased some CrownCote vapor barrier, an ultra-low-viscosity epoxy. "I start by grinding the floor to get a nice tooth-surface prep is really important. Then I take the vapor block squeegee it on and it just disappears into the concrete. It really gets into the concrete and takes a bite. I keep putting it on until it builds up a 25 to 35 mil layer on the surface then I back roll it and it self levels." The next day he returns and places an epoxy coating, which he also gets from Crown Polymers. While the epoxy is still wet, he broadcasts sand onto the surface until it no longer wets from the epoxy. The following day he vacuums up the loose sand, leaving the floor looking like a sheet of sandpaper. "The epoxy attaches to the vapor block and once I broadcast the sand into it I have a tooth to attach my overlay whether it's a microtopping or a thin topping."The initial preparation of the floor is a critical part of the process. "Some floors are so ugly we have to go in first and chase the cracks and fill them with liquid epoxy," he said. "I keep filling the cracks until I get them full before I put the vapor block on. For surface preparation, bead blasting is by far superior, but there's an $1100 minimum to bead blast. So on smaller jobs, we grind the surface to open it up then do an acid etch with muriatic acid. You can also sand blast if you have an open air area."Today Pettigrew won't even accept a job unless he's allowed to include this as part of the process. "It may seem like a lot of extra work," said Pettigrew, "but anybody who has had to go back and fix one of these floors after they've finished their beautiful artwork overlay knows that two days is nothing compared to the nightmare you have if it starts coming up." The extra cost typically totals about $3.00 per square foot-75 cents for surface prep, $1.00 for the penetrating vapor block, 35 cents for the epoxy, and the rest is labor. Pettigrew has been using this method for several years. "I've never had any problem with an overlay after I've done this."

City of Louisville, Colo., had just one potable storage tank. To increase storage capacity to 8 million gallons, the Public Works department built a 3 million gallon tendon-prestressed concrete tank and converted the old tank into a chlorine contact basin that feeds the new tank. Even so, Colorado's weather took its toll on the half-century-old original tank. DRP Consulting Inc., a Boulder Colo., firm that specializes in concrete petography recommended modification rather than complete replacement of the tank.To give incoming water sufficient chlorine contact time, the team recommended building a series of floor-to-ceiling concrete baffle walls within the tank. In addition to allowing water to flow from one end of the tank to the other, the 8-inch-thick walls could be used to extend the structure’s life by supporting the deteriorating roof.

Heating your home with a forced-air furnace isn't your only option when you have concrete floors. You can save energy and create a healthier, more comfortable living environment by having the floor itself distribute the heat-from the ground up-via a radiant in-floor heating system.The science behind radiant floor heating is quite simple: Tubes that circulate hot water or electrical heating elements are installed in the concrete slab when it's poured, turning the thermal mass of the concrete into an inconspicuous radiator of warm, even heat. Among the many benefits: Your feet are always toasty warm, the temperature is consistent and easy to control, you won't feel the drafts or hear the noise of blowing air, and no dust or allergens get circulated within your home through air vents. Best of all, you'll typically pay lower utility costs than with a forced-air system, because concrete floor radiant heating consumes less energy to achieve the same level of comfort.What if you have an existing concrete floor? Radiant heating is still an option. Newer ultra-thin electric heating mats are available that can be embedded in thin-set cement or gypsum overlays, allowing retrofitting over existing slabs without significantly raising the floor height. Here is more information about what radiant in-floor heating is, how it works, the benefits of radiant heat and where to find installers.

Dividing backyard space into outdoor "rooms" is a growing trend in landscape and hardscape design with the biggest focus being on the outdoor kitchen. No longer just a barbeque counter or the lone charcoal grill, the outdoor kitchen is growing in size and functionality as it steals the spotlight and becomes a main focal point in the backyard. In this article, Scott Cohen, HGTV's favorite Garden Artisan, shares his insight on how to design today's trendy outdoor kitchens.Nowadays outdoor kitchens are a more elaborate extension of the indoor kitchen and far more sophisticated than a simple charcoal grill. Outdoor kitchens need to be sized appropriately for the space available while meeting the entertaining and dining needs of the homeowner.Start with this list of questions to help define the parameters for your design:Entertaining needs: These questions will help you size the counter.How often do you grill?How many people do you entertain on a regular basis outdoors?At big parties?Will you need to be able to accommodate a bartender and/or caterer?Equipment Wish ListHow large of a grill do you plan to use?What outdoor kitchen accessories and appliances do you want to include in your layout?ConfigurationDo you want the counter built at one height or create a split level counter with a portion of the counter at bar height?How many people do you want to be able to have at the bar counter?PlacementIs there an area in the yard that you think would perform best for the outdoor kitchen?From which direction does the prevailing wind come?What are the sun and shade angles in the yard ?

If you’re in the process of having a home built or are planning a remodeling project, countertops may have been something that’s crossed your mind. While there are many popular countertop options, you may not have considered concrete as one of them. When people think about concrete, they typically picture outdoor areas such as driveways and pool decks. And when people dream of new countertops, their minds drift to granite. Concrete shouldn’t be underestimated though. Concrete is a durable and affordable material that is used in a number of ways in and around homes today. Consider implementing it for your next project involving countertops. Below are some of the reasons why it can serve as a great alternative to traditional granite countertops.   DurableThere are so many benefits to concrete that make it ideal as a countertops material, especially in kitchens. Concrete countertops are stain and heat resistant. Imagine not having to worry about accidentally staining your new countertops with food, or placing a hot pot or pan on them. The same goes for concrete countertops in a bathroom — no more worries about makeup that may stain, or hot styling tools that are used on a daily basis.     VersatileAt Creative Concrete Solutions, we offer two different types of concrete countertops. Choose between a cast concrete countertop or a concrete overlay. A cast concrete countertop is made from cement and internal reinforcements such as structural steel, strong fibers, or another material that will hold the slab together. With an overlay, a concrete mixture will be placed over your existing tile or laminate countertops, which is the more cost effective option of the two. With the overlay option, you won’t have to do a complete removal of your existing countertops, like you would for a granite countertop installation. Affordable Concrete is an affordable material for countertops. It can be designed to replicate the look of granite and other natural stones. You’ll get a cost effective design that’s one-of-a-kind. No matter whether you choose a cast concrete countertop or the less expensive overlay, you’ll get the same stain and heat resistant benefits of concrete.  It’s Similar to Granite at Half the CostWhile you may have been dreaming about granite countertops, as many do, concrete is an amazing material that can look just like granite for a fraction of the cost. As mentioned above, it’s a forgiving material that can be made to go with any kitchen or bathroom’s style. If you give concrete a chance you won’t be disappointed with the way it looks and performs inside of your home. This isn’t your average concrete, after all. 

Concrete Countertop Solutions Inc., creators of the Z Counterform and Z Poolform Systems have released two new revolutionary products today. First up is their new White Countertop Mix which will replace the one they are currently selling. This new mix is formulated to be even whiter, stronger, and easier to use than before. It now uses 50% crushed marble aggregate and is able to achieve over a 9800 psi compression strength. It is highly flowable and works incredibly well with their FG50 Fiberglass Mesh and Z Clip system. It’s nearly self-leveling for cast-in-place or pre-cast pours. This mix also has an extremely high flexural strength that allows it to be cast under 1” thick. Because this mix is able to be cast as thin as 7/8” for a countertop application, its release is coinciding with the launch of their new thinner edge form: the EuroForm. It is a similar design to our popular Square Edge Form however the front edge is only 1-1/4” thick. “This thinner edge profile has become very popular in the European market and we see it catching on here as well,” said Ed Baldoni, owner of CCS. “Our European distributor has been asking us to come out with this thinner form for quite some time but our biggest hiccup was the mix. We needed something strong enough that could be poured at 7/8” and not sag or crack under the stress of the spans and overhangs of a standard countertop. Today we are proud to announce that this product finally exists and it is by far the nicest and easiest mix I have ever used for concrete countertops.” In addition, CCS is releasing a new Z Clip and Faucet Knockout which will work with the EuroFrom and a Bright White Color-Pack. This Color-Pack can be added to the White Countertop Mix to make it even whiter. This is ideal for customers looking for the whitest possible solution or who will be polishing the concrete which will make the concrete appear less white.

A T-shirt that can change color to complement your mood (and help you pare down your wardrobe). An apron that transforms into a dress and has interchangeable pockets with high-tech functionality. These are the forward-looking concepts presented by a group of three students from MIT and three students from the Fashion Institute of Technology (FIT), making practical use of the latest active textile technologies.For the first FIT/MIT Summer Workshop, held over two weeks in June, the six students spent one week at MIT in Cambridge, Massachusetts and one week at FIT in New York City to explore and develop clothing concepts using advanced functional materials that incorporate 3-D printing or advanced knitting technologies. The workshop was held collaboratively with Advanced Functional Fabrics of America (AFFOA), a Cambridge-based national nonprofit enabling a manufacturing-based transformation of traditional fibers, yarns, and textiles into highly sophisticated integrated and networked devices and systems.Personal identityVeronica Apsan, of Park Ridge, New Jersey, a 2018 FIT graduate who majored in fashion design, and Erika Anderson of Carlsbad, California, a rising MIT senior who is studying mechanical engineering with a minor in design, conceived a T-shirt that can change color.“We were really interested in color and how it affects people’s moods and how they feel,” said Anderson. “Color and clothing are part of a person’s identity and how they want to portray that to the world.” Anderson and Apsan started with a color-changing filament that they 3D-printed into modular components. From there, they moved on to hollow fibers that can be filled with an ink that changes color when an electrical current is sent through it.“Many people own basic clothing or similar shirts and pants in different colors,” Anderson explained. “This takes up a lot of closet space and costs a lot of money.” A large wardrobe is also not environmentally friendly. With a T-shirt that can change color, a person could radically pare down how many garments they buy and throw out.The four other students in the workshop combined their ideas into a single wearable concept. David Merchan, of Bow, New Hampshire, a rising MIT senior double majoring in materials science and engineering and physics; Melanie Wong of Queens, New York, a rising senior at FIT majoring in fashion design; Calvin Zhong '18, of Manhattan, a recent MIT graduate who double majored in architecture and comparative media studies; and Jesse Doherty, an FIT rising senior majoring in fashion design, created a double-layer knit laboratory apron with reflective zippers that transforms into a dress or bag and has interchangeable pockets with customizable technological functions. For example, one pocket could have an energy socket that wirelessly charges a phone, while another could act as a hand sanitizer by working into the fiber antimicrobial chemicals or ultraviolet LEDs. The apron/dress itself could also be infused with conductive fibers that cool or warm the wearer.“You could imagine that a lab tech would have different needs than a doctor, who would have different needs than a DIY hobbyist or a shop manager,” explained Zhong.3-D-printed meshUsing 3-D printing, the students knit an open, fully twistable weave mesh for their apron/dress. Once the soluble supports were removed in a chemical bath, the mesh moved in every direction because of the flexible fiber. “The same structure in different materials would behave differently,” noted Doherty.In addition to conceiving their projects, the students had a packed schedule of workshops, talks, and site visits. While at MIT, they learned about bringing their ideas to market through an intensive entrepreneurship boot camp. They also attended an AFFOA member networking event at the Institute of Contemporary Art in Boston, where Apsan said she and Anderson received positive feedback about their ideas. “The fact that someone in the industry who is working on textiles is thinking the same thing was so awesome to hear,” she said. During their week at FIT, the students visited WGSN, a leading fashion trend, forecast, and analysis service, and met with Gabi Asfour, founder and creative director at threeASFOUR, a clothing design brand, about incorporating 3-D-printed parts into garments. MIT and FIT faculty mentors assisted the students throughout the two weeks.“We believe this is the future, so we want you all to be involved and help make it happen,” AFFOA Chief Executive Officer Yoel Fink told the group.Inspiring collaborationGregory C. Rutledge, lead principal investigator for MIT in AFFOA and the Lammot du Pont Professor in Chemical Engineering, commented, "It is exciting to see what happens when students from different fields of engineering and design, but with a common interest in advanced fibers and fabrics, come together and engage with new kinds of materials and manufacturing techniques. The collaboration and creativity is inspiring.”“Combining the talents and skills of FIT and MIT is truly the future,” said Apsan as the two-week workshop wrapped up.“This workshop validates the benefits of bringing FIT and MIT students together. For this specific workshop, the students explored the possibilities of advanced knitting and 3-D printing,” said Joanne Arbuckle, deputy to the president for industry partnerships and collaborative programs at FIT. “As the fashion industry becomes more and more dependent on advanced textiles, students who have the experience this workshop has provided will prove to be the industry’s next leaders.”

In 2009, the American Society of Civil Engineers (ASCE) assigned a grade of “D” to the overall quality of infrastructure in the United States, saying that ongoing evaluation and maintenance of structures was necessary to improve that grade. Since then, federal stimulus funds have made it possible for communities to repair some infrastructure, but high-tech, affordable methods for continual monitoring remain in their infancy. Instead, most evaluation of bridges, dams, schools and other structures is still done by visual inspection, which is slow, expensive, cumbersome and in some cases, dangerous.Civil engineers at MIT, working with physicists at the University of Potsdam in Germany, recently proposed a new method for continual electronic monitoring of structures. In papers appearing in the journals Structural Control Health Monitoring and Journal of Materials Chemistry, the researchers describe a flexible fabric with electrical properties that could adhere to areas prone to cracking — such as the undersides of bridges — and detect cracks almost immediately when they occur.Installing this “sensing skin” would be as simple as unrolling it and gluing it to the surface of a structure. The rectangular patches on the skin that detect changes in its electrical charge could be tailored in a geometric design appropriate for the type of crack likeliest to form in a particular part of a structure: for example, diagonal square patches to detect cracks caused by shear, or horizontal patches to detect the cracks caused by a sagging horizontal beam.The formation of a crack would cause a tiny movement in the concrete under the patch, changing the capacitance, or stored energy, of the sensing skin. Once a day, a computer system attached to the sensing skin would send a current to measure the capacitance of each patch and detect any difference among neighboring patches. In this way, it could detect a flaw and its exact location within 24 hours — a task that has proved difficult for other types of sensors proposed or already in use, which tend to rely on detecting global changes in the entire structure using a few strategically placed sensors.“The sensing skin has the remarkable advantage of being able to both sense a change in the general performance of the structure and also know the damage location at a pre-defined level of precision,” says Simon Laflamme PhD ’11, who did this research as a graduate student in MIT’s Department of Civil and Environmental Engineering. “Such automation in the health-monitoring process could result in great cost savings and more sustainable infrastructures.” Laflamme worked with Jerome Connor, professor of civil and environmental engineering at MIT, and University of Potsdam researchers Guggi Kofod and Matthias Kollosche.The researchers originally tested their idea using a commercially available, inexpensive stretchy silicon fabric with silver electrodes. While this worked in some lab experiments performed on both small and large concrete beams under stress, the material ultimately proved too thin and flexible for this application. The researchers have now developed a prototype sensing skin made of soft stretchy thermoplastic elastomer mixed with titanium dioxide that is highly sensitive to cracks; painted patches of black carbon measure changes in the electrical charge of the skin. A patent for the sensing method has been filed.“The innovation of this proposed sensor design is in its use of a material that provides mechanical flexibility and serves as a capacitor,” says Professor Tzu-yang Yu of the University of Massachusetts at Lowell, a structural engineer who specializes in the mechanical analysis of structures and the design of nondestructive methods for testing infrastructure. “This design allows the sensor to overcome the difficulties associated with conventional piezoelectric sensors which have strict contact conditions between the sensor and the structure’s surface. The proposed sensor is also superior to conventional fiber-optic sensors in the way that two-dimensional readings can be collected from one sensor.“Like all innovations in the development stage, there are additional issues this sensor needs to address, such as instrumentation, packaging and environmental vulnerability. Naturally, the next step would be to perform a small field test in order to investigate the field performance of the sensor,” Yu says.“Many of the types of infrastructures graded by the ASCE are made of concrete and could benefit from a new monitoring system like the sensing skin — including bridges, which received a ‘C’ grade, and dams and schools, which earned ‘Ds,’” Connor says. “The safety of civil infrastructures would be greatly improved by having more detailed real-time information on structural health.”The work of Kofod and Kollosche was funded by the German Ministry of Education and Research.

When the Mactaquac Dam opened in New Brunswick, Canada, in 1968, it was expected to have a service life of 100 years, but a chemical reaction occurring within the concrete used to build the dam has drastically shortened that timeline.“Concrete is a mix of cement, crushed rock, sand, and water. Alkali-silica reaction, the cause of the major issues in New Brunswick, occurs when alkalis in the cement pore solution encounter reactive forms of silica in the rock used to make the concrete,” explains Jeremy Gregory, executive director of the MIT Concrete Sustainability Hub (CSHub). “The reaction produces a gel which expands as it absorbs water and exerts pressure that can cause cracking and result in structural problems in concrete infrastructure.”Researchers from the CSHub, the University of New Brunswick (UNB) and Oregon State University (OSU) have teamed up on a project to address several concrete durability issues, including alkali-silica reaction (ASR). Researchers at UNB are conducting ASR experiments, while OSU researchers are leading work on another durability issue known as freeze-thaw. Most of the project’s computational work is done at MIT, along with some experimental measurements.“Our research collaboration looks at understanding ASR from fundamental building blocks,” explains Thomas Petersen, a grad student in the MIT Department of Civil and Environmental Engineering and research assistant with the CSHub. “Starting from an atomistic description, we wish to understand the mechanisms leading to the expansion of the bulk concrete composite. Is the gel expanding? Is the CSH [calcium-silicate-hydrate] expanding? We are looking to answer these questions by understanding the molecular configurations of the materials.”The team visited Mactaquac during a meeting in August. Petersen says the visit offered a great opportunity to learn about the potential impact of the team's research on infrastructure systems. CSHub postdoc Laurent Béland agrees, noting that observing the “crazy expansion” at Mactaquac in person rather than in pictures, made the sometimes-abstract ideas he explores, more, well … concrete.“Seeing the impacts of ASR on a structure that large, in person, makes you realize how big this problem is; not only is this major dam supplying electricity, it’s making sure a pretty big city won’t be flooded,” says Béland. “As an atomistic simulation expert, I’m coming at this from one perspective. Working with people to be able to absorb what this is all about, you see the research impact scaled up.”The Mactaquac Dam has swelled some 9 to 12 inches in height since it was constructed 50 years ago. Cracking is visible throughout the structure, but the issues extend well beyond the concrete.“There are gates that no longer close — there’s a seven- or eight-inch gap,” says Béland. “There are also places where engineers have had to cut through the dam to relieve pressure and, for obvious reasons, you’d prefer that dams not have to be cut into.”Additionally, the dam’s turbines, which are used to generate hydroelectric power, need to periodic adjustments to prevent contact with the blades, and the steel beams and columns that help house the turbines and shafts must also be occasionally readjusted to maintain stability. Engineers are working to keep the dam in operation through the end of its intended service life, roughly the year 2068. These efforts are costly. Petersen notes, “A full-time engineering unit and $8 million per year are needed to maintain the dam and ensure its health into the future.”The civil engineers and cities planners who built the Mactaquac Dam did test the aggregate for susceptibility to the alkali-silica reaction, however they did not test under conditions that well represented the conditions of the dam. The industry is still seeking fast, reliable testing methods for ASR that take such factors into account, something the CSHub-UNB-OSU durability project hopes to achieve.“The benefit of working on applied topics is that the consequences of diligent and informed engineering practices is vividly portrayed in our everyday life," says Petersen. “By advancing our modeling techniques and testing procedures, mistakes in the design of the Mactaquac dam can be avoided in the future.”CSHub researchers Alice Dufresne, Thibaut Divoux, and Michael Heist recently published research briefs relating to the team’s ASR work. The publications, entitled "Atomistic Modeling of ASR Gel" and "Mechanical Properties of Alkali Silica gels, "are available on the CSHub website.

OSHA has proposed a rule to eliminate the requirement for companies to submit information from its electronic recordkeeping procedures.The move comes in an effort to protect personally identifiable information or data that could be associated with a particular individual.The proposed rule eliminates the requirement to electronically submit information from OSHA Form 300 (Log of Work-Related Injuries and Illnesses), and OSHA Form 301 (Injury and Illness Incident Report) for establishments with 250 or more employees that are currently required to maintain injury and illness records.These establishments would be required to electronically submit information only from OSHA Form 300A (Summary of Work-Related Injuries and Illnesses).Under the current recordkeeping rule, the deadline for electronic submission of Calendar Year (CY) 2017 information from OSHA Forms 300 and 301 was July 1, 2018.In subsequent years, the deadline is March 2. OSHA is not currently accepting the Form 300 or 301 data and will not enforce the deadlines for these two forms without further notice while this rulemaking is underway. The electronic portal collecting Form 300A data is accepting CY 2017 data, although submissions after July 1, 2018, will be marked late.

Chaney Enterprises, ready-mix concrete, aggregates, and custom blends supplier, announces its partnership with CarbonCure Technologies to help reduce the carbon footprint of their concrete products.During manufacturing, the CarbonCure technology chemically mineralizes waste carbon dioxide (CO2) and injects it into the concrete. The process improves the concrete’s compressive strength, reducing cement content while maintaining compressive strength requirements.To date, Chaney has delivered approximately 9,000 cubic yards of concrete made with CarbonCure to jobsites across Maryland. Approximately 160,000 pounds of CO2 have been saved so far this year, which is equivalent to the amount of CO2 sequestered by an acre of U.S. forest over 85 years.“Partnering with CarbonCure allows us to help our customers reduce the carbon footprint of building developments, while continuing to provide the high-quality concrete and high-caliber service they expect from us,” says Concrete Operations Manager of Chaney Enterprises, Jeff Slagle.Chaney provides ready-mix concrete, sand, gravel, stone, blended soils, and related construction supplies to customers throughout Maryland, Northern Virginia, and the Delmarva Peninsula.

It isn’t often that the construction industry leads in new technology adoption, yet that is the opportunity offered by a new partnership between Viewpoint, a leading construction software provider, and Nvoicepay, a B2B payments automation company. Full disclosure: I recently joined Nvoicepay because I knew that integrating their payments automation technology to Viewpoint’s system was the solution a lot of construction companies have been wanting. This a relatively new technology category and early adopters can use it to gain a significant competitive advantage.It’s been a long time coming.I’ve been selling software and services to the construction industry for about 25 years, both to residential and commercial builders. My first exposure to the payments process was in 2000 when I went to work for a company that was trying to build an e-commerce hub—what today you’d call a marketplace or platform—for home builders, manufacturers, and suppliers.Flaming outWe got a quarter of a billion dollars in venture money and flamed out after two years, for a few reasons. Looking back, it was just way too early. These kinds of three-way marketplaces are everywhere now, but it took cloud technology and massive increases in computing power to be able to build them at scale.Even if we had had the technology, I don’t think that the home building industry, save for a few of the national publicly traded builders were big enough and sophisticated enough that it would have made sense to them to invest in something like that at the time. There were a lot of manual processes, and almost all payments were made by check, but construction companies tend to invest more in equipment than technology. It would have been a hard sell.Moving the needleI went back to selling construction software but got back into the payments side in 2009 when I went to work for a company selling Mastercard into ERPs for commercial construction.Banks were selling similar card programs, but what my company at the time did well was hire people, like me, that knew the industry and could understand how integration would work with their ERP system. We could also look at a contractor’s vendor master and be able to identify vendors that we knew would take a card, so we could quickly calculate the rebates they would get based on their spending with those vendors.We understood the pain points better, and so we were able to connect and make the business case for card payments in a different way that banks were doing. We did an excellent job of exposing a lot of construction companies to the idea that they didn’t have to pay everyone by check.Seeing the bigger pictureI wanted to broaden my exposure to more industry verticals, and to more global electronic payment technologies, so I next took a job with Visa to work with banks on electronic payment strategies. What I saw was a lot of complexity. Smaller banks were either looking to adopt an electronic payment solution for the first time or upgrade their existing offering to a more modern platform.Many of the big banks were managing multiple payment solutions to target mid-market and enterprise segments. Some were EDI-based; some were tied to treasury management solutions; some of them were based around corporate cards, some around ACH. Banks had invested a lot of time and money building in-house payment platforms, and it seemed that many were at a crossroads, trying to determine whether they should continue to put resources toward these platforms or adopt a third-party solution.One thing that became very clear to me was that electronic payment solutions were evolving quickly, and fintech firms, not banks, were on the leading edge. Visa, like Mastercard, was and is proactively partnering with these fintechs to enable virtual cards as a payment option in their solutions. Eventually I made my way to Nvoicepay where I’m helping launch and grow their new Viewpoint partnership. I heard about how they were innovating the construction industry through supplier payment automation and I knew this was something I wanted to be apart of.Toward a new payments paradigmThe construction industry has come a long way regarding accepting electronic payments, and it’s cool to have been part of that trajectory. In this industry, getting an invoice approved for payment is much more complex than in other industries. You don’t just have people in the back office who have to approve payments. You have construction managers out in the field who have to confirm what percentage of the work has been completed, which will dictate they payment amount.There’s a lot of communication that has to happen, and a lot of room for error.Construction companies are starting to realize that the AP department should be spending its time making sure that they’re paying the right invoices in the right amount at the right time. The last mile, the printing of the check, the stuffing of the envelope, or the assembling of files for ACH and card payments and keeping track of who gets paid how is a low-value activity.If that whole piece can be outsourced to one company that can maximize card payments and rebates, set up ACH for vendors that won’t take cards, and issue checks for those holdouts who still want paper, that’s a tremendous value proposition.We were trying for that way back in 2000; we made headway in card payment acceptance over the next decade or so. Now with the evolution of technologies like optical character recognition that can digitize paper invoices, and workflow software that can move invoices through the approval process, the front end has pretty much been automated. That cleared the way for a company like Nvoicepay to come along and automate executing the payment—not just card payments, or ACH payments but any type of payment. When I saw that, I thought, “If you can’t beat ’em, join ’em.“

It’s hard to ignore the recent press that this topic has been generating in response to one of the hottest summers that Europe has experienced in decades. Buildoffsite have hit back at challenges to the performance of lightweight modular homes. Bob Ward, policy and communications director at the LSE's ESRC Centre for Climate Change Economics and Policy and deputy chair of London Climate Change Partnership (LCCP), in a recent article published in the Guardian, has expressed equal passion about his serious concerns about the risk of overheating.The Concrete Centre understands the unease of Bob Ward, who wrote “As ever, those who are least able to deal with the problems are quite often the ones most deeply affected by them, and when developers cut corners on design, occupants usually pay the price”.Building Physicist and thermal performance expert at The Concrete Centre Tom De Saulles’ is of the view that the Environmental Audit Committee were right to instigate the Heatwave Inquiry and subsequently express concern about overheating and modular homes in their recent report entitled ‘Heatwaves: adapting to climate change’. Tom said “the Committee is right to express unease about the overheating issue in respect of modular homes, this can be more of an issue in lightweight homes that have little inherent thermal mass.The guidance we provide to designers about how to use thermal mass, when used in combination with shading and ventilation for cooling in summer is essential in managing the risks of overheating. Although these passive measures may need to be supplemented with active cooling in some climate change models and in some building types, such as high-rise apartments, these important performance criteria should not be compromised as we try to meet the undoubted and urgent need for more housing”.The Concrete Centre provides technical guidance on reducing overheating and in the past has worked with the Zero Carbon Hub and is now working with the Good Homes Alliance to provide evidence-based best practice to planning departments on the risks of overheating. Tom continues “It is so important that proven performance and evidence shapes this debate, to provide housing that is resilient to climate change and will perform now and in the future”.The Environmental Audit Committee report, which says “modular homes are not resilient to heatwaves”, recognises that many factory-produced homes are of lightweight construction and lack thermal mass.Andrew Minson, Executive Director of The Concrete Centre added “Unsurprisingly those in the offsite sector who produce lightweight systems are not happy about the Committee’s stand on this point, but the fact remains that thermal mass offers an effective means of helping reduce overheating when used in conjunction with good ventilation and solar shading.If we are going to tackle the problem of heatwaves without resorting to energy intensive air conditioning then we are going to need to employ all the passive measures available to us, of which thermal mass, inherent in masonry and concrete, has an important role to play.”

Problem: Last night the temperature fell to 45 degrees. This morning I started getting calls from contractors about spider web cracking on their slabs. “I thought this kind of crack only occurred during hot weather. It never even got over 70 degrees yesterday. What happened?”Answer: What you’re probably referring to is known as plastic shrinkage cracking. While such cracks typically occur during hot weather, they can also occur in cold weather. In fact, I get calls on this almost every fall when the first cold snap comes through. One good thing is that these cracks are only on the surface and are not structural.To understand why a hot weather problem occurs during cold weather, we have to understand what causes it. When water evaporates from the surface of the slab faster than bleed water can replace it, the top surface starts to shrink and crack. This happens before the concrete has begun to set up, which results in the cracks being small and close together. Things that cause surface moisture to evaporate faster or delay the rise of bleed water increase the probability of plastic shrinkage cracks. (For a more thorough discussion, see ACI 305R-10, “Guide to Hot Weather Concreting,” or NRMCA CIP 5, “Plastic Shrinkage Cracking.”)ACI 305R-10 contains a well-known nomograph that predicts the likelihood of plastic shrinkage cracks. This nomograph uses the following information to predict whether or not plastic shrinkage cracks are likely to occur:Air temperatureRelative humidityConcrete temperatureWind speedWhenever the chart predicts water will evaporate at a rate approaching 0.2 pounds/square foot/hour (lbs./sq. ft./hr.), the likelihood of plastic shrinkage cracking exists. Of course, other factors, such as elevated air content in the concrete or the presence of fly ash or microsilica, also affect the occurrence of plastic shrinkage cracks. However, ACI’s nomograph is a pretty fair indicator for everyday concrete.So why does this hot weather phenomenon affect concrete during the fall? For the same reasons your lips dry out and crack during winter.Relative humidity often drops during cold weather, which increases evaporation rate. In Texas, where I live, it’s not uncommon for an 85-degree day to be followed by a nighttime cold snap that drops ambient temperature to 45 degrees. Concrete placed the next morning will still be at 85 degrees to 90 degrees, but the ambient temperature will be 50 degrees with a relative humidity of 35%. Let’s say there’s a nice, brisk 15 mph breeze. According to the ACI nomograph, the concrete can be expected to lose about 0.40 lbs. of water/sq. ft./hr. – more than twice the amount needed to cause plastic shrinkage cracks.Fortunately, you don’t have to carry around a copy of ACI 305 to do these calculations. The free “ACI Mobile” app for Apple has a section called “Job Site Weather & Curing” that does these calculations for you. In this example, the screen’s yellow background indicates that, based on the day’s weather conditions, there is a moderate probability of plastic shrinkage cracking. Thursday through Saturday are green, indicating a low probability. Red indicates a high probability.How do you prevent plastic shrinkage cracks? The best plan for contractors is to follow ACI 305 or NRMCA CIP 5, “Plastic Shrinkage Cracking” recommendations on how to reduce excessive evaporation. One thing I have seen concrete producers do is place a pump-up sprayer filled with an evaporation retardant on each truck and rent those out to contractors as a value-added item. Note: An evaporation retardant is not the same as a curing compound. As the producer, if you have any doubts about the proper material to use, check with your local concrete chemical supplier or local ready-mix association chapter.Plastic shrinkage cracks won’t affect the structural integrity of a slab or pavement, but they can be unsightly and ultimately affect longevity. Because you can’t do much to prevent these cracks, your best course of action is to educate contractors.

The gel effectively lifts a wide range of one-part topical coatings, such as sealers, acrylics, urethanes, latexes, and lacquers, from concrete, and masonry. Ultrite Coating Remover removes multiple layers in one application without vigorous scrubbing. It does not contain methylene chloride, is low odor, and is safe for interior use in warehouses, industrial plants, parking garages, and plazas. Use the Ultrite Cleaner to remove the residues left from Ultrite Coating Remover.

The information age has a puzzling way of disrupting outstanding information sources, such as The Concrete Producer. After serving the concrete production and precast industry for more than 35 years, the magazine, website, and newsletter will no longer exist as a standalone title after August 2018.Over the years, those who have contributed to TCP sounds like a who’s who of the concrete industry: Bruce Suprenant, Rick Yelton, Ward Malisch, Terry Holland, Frank Kozeliski, Colin Lobo, Jay Shilstone, Mary Hurd, John Albinger, Bob Garbini, Pierre Villere, Craig Yeack. The magazine’s editors have included Terry Holland, Rick Yelton, Shelby Mitchell, and Tom Bagsarian. The publication, that started out as The Concrete Journal then became The Concrete Producer in 1995, explained the intricacies of concrete production and delivery and celebrated the industry's leaders.The archived content of TCP will remain available on Concrete Construction’s web site and the always-popular columnist Pierre Villere will continue to write a monthly column that will appear in CC’s Industry Update newsletter. All unique subscribers to TCP's Update newsletter will be automatically signed up to receive CC's newsletter. You can also subscribe to that newsletter by clicking here. Pierre has written a heartfelt farewell column, End of an Era, that you can read here.The end of The Concrete Producer as a magazine is troubling to me, but we really had no choice. It simply wasn’t making a profit anymore. While the ready-mixed concrete business continues to thrive, and the demand for information has never been stronger, the industry apparently is looking elsewhere and using different techniques to convey its message. Our world is changing at a blistering pace and some things, like magazines, get left behind.

The International Grooving & Grinding Association (IGGA) – a non-profit organization dedicated to serving as the leader in developing optimized pavement surfaces and the technical resource in support of diamond grinding and grooving as well as concrete pavement preservation – in conjunction with the Cement Council of Texas – the non-profit trade association of portland cement manufacturers and shippers in Texas – announced the winner of their Government Official of the Year Award.The employees of the Texas Department of Transportation – Houston District were selected as this year’s winners of the national award. They were recognized for their efforts in advancing the understanding and use of quiet concrete pavement surface textures utilizing the Next Generation Concrete Surface in the state of Texas.The award ceremony took place at the 2018 TxDOT-CCT Concrete Conference held April 9-11, 2018 at the J.J. Pickle Research Campus at UT-Austin, Texas. The technical program, co-hosted by the Texas Department of Transportation (TxDOT) and the Cement Council of Texas (CCT), is held every two years and shares information on concrete highways, bridges and local streets and pavements.A technical presentation by TxDOT discussed how the Houston District—the largest DOT district in the state—incorporated the ultra-quiet and smooth Next Generation Concrete Surface (NGCS) into several major highways, including I-10, Harris County’s U.S. 290, and the 610 Loop. Houston is placing approximately 3 million square yards of NGCS in total.“TxDOT had been urged to apply a pervious friction course on top of the new concrete on 290, as well as on the 5-year-old pavement of I-10. However, this overlay would have added expense to the project and also set the roads up to require regular maintenance—as often as every seven years. Texas has extensive experience using continuously reinforced concrete pavement (CRCP) in its populated areas and has found that CRCP, if well-constructed, is an extremely low-maintenance, economical option. This made them eager to stick with concrete pavement solutions,” said Jan R. Prusinski, executive director of the Cement Council of Texas.TxDOT turned their attention to NGCS, an innovative solution which the department knew had performed well in research and trial applications.“This award is an acknowledgment of the Houston District of the Texas Department of Transportation’s ability to recognize the needs of the homeowners in the area and take positive, decisive steps to make their lives better. Their willingness to innovate and adopt new technologies to meet these needs sets this group apart and makes them a model for other pubic agencies to emulate. Congratulations to all receiving this well-deserved award!” said John Roberts, executive director of the International Grooving & Grinding Association.“An eventual goal for TxDOT is to re-examine the use of sound walls along highways,” said Prusinski. Sound walls are often ineffective, because it is impractical to position them in the exact locations where they are needed to interrupt sound waves. Landscape features such as biosystems and waterways, along with difficulties in property acquisition, etc., can result in gaps between sound walls and sub-optimal layout. Additionally, the installation and maintenance of sound walls is expensive.Approximately 270 people attended this year’s conference, with approximately 100 representing TxDOT engineering and construction personnel and the remainder being local transportation personnel, consultants, manufacturers and suppliers, and others.About IGGAThe International Grooving & Grinding Association (IGGA) is a non-profit trade association founded in 1972 by a group of dedicated industry professionals committed to the development of the diamond grinding and grooving process for surfaces constructed with Portland cement concrete and asphalt. In 1995, the IGGA joined in affiliation with the American Concrete Pavement Association (ACPA) to form today what is known as the IGGA/ACPA Concrete Pavement Preservation Partnership (IGGA/ACPA CP3). Today this partnership serves as the technical resource and industry leader in the marketing of optimized pavement surfaces, concrete pavement restoration and pavement preservation around the world. The mission of the IGGA is to serve as the leading technical and promotional resource for the acceptance and proper use of diamond grinding and grooving as well as PCC preservation and restoration. 

The three award-winning projects in the third-annual Quikrete One Bag Wonder contest combined function and flare to beat out arguably the most competitive field to date. Ed Trapper and Ron Norton took top honors with their Drink Caddy, which is based on the premise that cooled concrete will act similarly to an ice pack. Mark Dunne’s mixed-medium Live Edge Side Tables finished second and Jacob Snyder’s retro Singer Sewing Machine Sink finished third.“Each year, the quality and creativity of the projects submitted into the Quikrete One Bag Wonder contest reach new heights, and this year is no different,” said Frank Owens, Vice President of Marketing for The Quikrete Companies. “The idea that concrete will not only make a great carrying case for beverages, but will actually keep them cool is an unbelievable concept brought to life in the Drink Caddy. The second place side tables and third place sewing machine sink are also wonderful examples of beautiful, one-of-a-kind concrete projects with a real purpose.”Quikrete One Bag Wonder 3.0 contest was judged by the Home Projects Council, a think tank of home improvement experts, and employees of Quikrete, the leading manufacturer of packaged concrete. First place won $2,500, second place won $1,500 and third place won $500. All three winning projects will be celebrated by Quikrete at the Haven Conference, an annual conference for leading design and DIY bloggers, in Charleston, South Carolina, from July 12-14.

Visiting my brother Sean in Traverse City, Michigan last week I was introduced to a new beer made at the Right Brain Brewery where he works part time (he teaches science to 7th graders in real life, so you know why he needs a couple of beers after work). When you’ve been figuratively immersed in concrete for as long as I have, anything that uses the term generates some interest. That’s why I had to try Concrete Dinosaur, a brown rye IPA. The story is that when they were excavating for the brewery in an old industrial area they dug up a big chunk of concrete that was vaguely shaped like a brontosaurus. Seemed like a good name for a beer, especially one that won the silver medal for best rye beer at the 2015 Great American Beer Festival.There are all kinds of concrete creatures out there, from gargoyles to garden bunnies. Tyler Ley from Oklahoma State University just sent me a concrete R2D2, which is now searching my garden in vain for C3PO. But the most famous concrete being of all is Concrete himself, who appears in 113 issues of the eponymous comic book series. Seems that a speech writer named Ron Lithgow was abducted by aliens while hiking and had his brain transplanted into a concrete-like super body capable of leaping long distances and eating almost anything. Concrete is virtually indestructible, just like concrete.And don’t forget about concrete music (musique concrète), a form of experimental electronic music that originated in France in the early 1900s. It is a “sound sculpture” that uses synthesized sounds from the real world and manipulation of recorded sound. The Beatles used this technique on one of their songs.You may have heard of Concrete Blonde, a California rock band starring singer-songwriter Johnette Napolitano. The name was intended to contrast their hard rock style and more introspective lyrics. They had a couple of nice songs, especially Joey.The rapper Tupac Shakur wrote an autobiography, not published until after his untimely death, The Rose That Grew From Concrete. “Did you hear about the rose that grew from a crack in the concrete? Proving nature wrong, it learned 2 walk without having feet. Funny it seems, but by keeping its dreams it learned 2 breathe fresh air. Long live the rose that grew from concrete when no one else even cared.”In films concrete seems to usually come across as a bad thing—people encased in concrete, concrete overshoes to weight down bodies, and concrete as a metaphor for gritty city life. The 2004 Finnish film Concrete Night is the story of a boy and his soon-to-be imprisoned older brother. The Variety review says, “This mawkish bummer about an ill-used teenage boy wandering around a surreally forbidding Helsinki is marred by a facile nihilism that trivializes the urban alienation it seeks to illuminate.” Not much to celebrate there!So concrete does get some recognition in popular culture but not always the respect it deserves. Too bad most people don’t realize that much of our culture couldn’t exist without concrete.

A cement manufacturer in the Midwestern US has implemented a novel power solution at a remote conveyor location that lacked convenient electrical access. The patent-pending design uses the kinetic energy of the moving belt to generate enough electricity to drive an automated dust suppression system, a pneumatic belt cleaner tensioner, and a series of air cannons, helping operators at the Illinois cement plant reduce fugitive dust and spillage, increase cargo flow efficiency, and minimise labour costs for cleaning and maintenance.The Martin® Roll Gen™ system is designed to create a self-contained mini power plant that allows operators to run electrical monitoring systems, safety devices and a variety of other components. Able to be retrofitted on existing idler support structures, the generator can be employed on virtually any steel roller. The device is considered a significant step toward eliminating power production obstacles, as conveyors move into the next generation of ‘smart systems’ that are predicted to be more sustainable and autonomous.The long rideConveyor #107-1 is the longest outdoor conveyor system on the Illinois Cement site, running 600 ft (182 m) and discharging either onto the #107-2 stack-out conveyor or the 250 ft (75 m) belt leading directly into the plant, based upon immediate production needs. It’s a 30 in. wide (762 mm) mechanically-spliced belt with a 35º trough that travels at about 400 ft/min. (2 m/sec.), conveying nearly 300 short tph (272 tph) of limestone.Material arriving from the quarry can be either wet, dry, and dusty – or anything in between, depending on the season and weather. The changing work environment presented challenges throughout the entire conveying system, with different weather conditions triggering various types of carryback. Cleanup was labour-intensive.“The primary cleaner blades we had in place wore quickly, causing spillage that required us to take personnel from other areas to clean the buildup,” explained Illinois Cement Maintenance Planner, Brian Brandner. “We were out there cleaning or adjusting the tension to minimise spillage a few times a week. When it got really cold, we wouldn’t have as many issues with dust or carryback, but the frost accumulation required us to keep the belt running at all times, which lowered the blade life and caused undue wear on the belt.”Phase one of the Martin Engineering solution involved placing a ‘smart’ dust suppression system at the transfer point between the 153 and 107-1 conveyors. Phase two included an automated, pneumatically-tensioned belt cleaner and air cannon system at 107-1’s discharge zone. Both components are powered by the Roll Gen System.To manage the dust, technicians installed a Martin® Surfactant Dust System at the transfer point between 153 and 170-1 to deliver a chemically-enhanced water spray as a topical treatment for material at the point of emission. Triggered by a sensor as soon as the load enters the transfer point, the system supports dust mitigation measures already in place to minimise the labour needed for maintenance and replacement of the dust collector cartridges.Cleaning the beltClose to the mid-point of the system, conveyor 107-1 begins a gradual 20 ft (6 m) rise and discharges into the transfer chute leading either to the stack-out conveyor feeding the storage area or the main conveyor entering the plant. At that transfer point, technicians installed a Martin® QC1™ Primary Cleaner XHD (extra heavy duty), tensioned with an Automated Blade System (ABS).Connected to a small 24 V DC air compressor and a control panel powered by the Roll Gen, the ABS pneumatic tensioner delivers precise monitoring and tensioning to reduce the labor typically required to maintain optimum blade pressure through manual adjustment. Equipped with sensors to confirm when the belt is running empty, the system automatically backs the blade away, minimising unnecessary wear to both the belt and cleaner. Upon detection of an empty belt, the system is set to run for one full belt rotation to clean the surface thoroughly before pulling away. The result is consistently correct blade tension with reduced power demand on start-up, all managed without operator intervention.“The new cleaner has been a game changer when it comes to the amount of maintenance, equipment wear and manpower for cleanup,” Brandner pointed out. “The blade is no longer just scraping an empty belt, which has extended its operational life and minimised wear to the belt face and splice.”Transfer chute flowWhile monitoring the results of the installation, Martin Engineering technicians observed that the decreased spillage resulted in a proportional increase in fines discharged down the transfer chute. Exposed to the outside environment, the chute began to form significant buildup along the sides, at the diverter gate and on the internal shelf meant to slow the flow of material. The technicians had a solution to this unexpected result, and to mitigate the buildup, they installed a Martin® Hurricane air cannon.“When there’s cargo flowing, the cannon fires about every ten minutes, which keeps fines from clinging to the walls and promotes proper flow,” Brandner said. “If the material is extra wet and building up faster than usual, we can just go over and fire it manually at any time.”ResultsThe use of multiple technologies working in tandem to control material flow and prevent fugitive particles has dramatically improved the material handling system’s efficiency. The modifications have helped Illinois Cement reduce labor and equipment expenses, considerably cutting the manpower needed to clean spillage along the conveyor path. The result is a cleaner, safer and more productive operation.“The entire project has been a success, particularly in how many man-hours we save in maintenance and upkeep,” Brandner concluded. “The tensioning system does a great job, and the Roll Gen puts out enough power that we’re considering adding an automated secondary cleaner and a vibrating dribble chute to capture even more carryback.”

Typically, when architects or engineers design a new building, it’s only at the end of the process — if ever — that a lifecycle analysis of the building’s environmental impact is carried out. And by then, it may be too late to make significant changes. Now, a faster and easier system for doing such analyses could change all that, making the analysis an integral part of the design process from the beginning.The new process, described in the journal Building and Environment in a paper by MIT researchers Jeremy Gregory, Franz-Josef Ulm and Randolph Kirchain, and recent graduate Joshua Hester PhD ’18, is simple enough that it could be integrated into the software already used by building designers so that it becomes a seamless addition to their design process.Lifecycle analysis, known as LCA, is a process of examining all the materials; design elements; location and orientation; heating, cooling, and other energy systems; and expected ultimate disposal of a building, in terms of costs, environmental impacts, or both. Ulm, a professor of civil and environmental engineering and director of MIT’s Concrete Sustainability Hub (CSH), says that typically LCA is applied “only when a building is fully designed, so it is rather a post-mortem tool but not an actual design tool.” That’s what the team set out to correct.“We wanted to address how to bridge that gap between using LCA at the end of the process and getting architects and engineers to use it as a design tool,” he says. The big question was whether it would be possible to incorporate LCA evaluations into the design process without having it impose too many restrictions on the design choices, thus making it unappealing to the building designers. Ulm wondered, “How much does the LCA restrict the flexibility of the design?”Measuring freedom of designTo address that question systematically, the team had to come up with a process of measuring the flexibility of design choices in a quantitative way. They settled on a measure they call “entropy,” analogous to the use of that term in physics. In physics, a system with greater entropy is “hotter,” with its molecules moving around rapidly. In the team’s use of the term, higher entropy represents a greater variety of available choices at a given point, while lower entropy represents a more restricted range of choices.To the researchers’ surprise, they found use of their LCA system had very little impact on reducing the range of design choices. “That’s the most remarkable result,” Ulm says. When introducing the LCA into the early stages of the design process, “you barely touch the design flexibility,” he says. “I was convinced we would come to a compromise,” where design flexibility would have to be limited in order to gain better lifecycle performance, Ulm says. “But in fact, the results proved me wrong.”The system looks at the full range of climate impacts from a new structure, including all three phases: construction, including examining the embodied energy in all the materials used in the building; operation of the building, including all of the energy sources needed to provide heating, cooling, and electrical service; and the final dismantling and disposal, or repurposing of the structure, at the end of its service.To evaluate the lifecycle impact of design choices requires looking at a wide range of factors. These include: the location’s climate (for their research, they chose Arizona and New England as two very different cases of U.S. climate); the building’s dimensions and orientation; the ratio of walls to windows on each side; the materials used for walls, foundations, and roofing; the type of heating and cooling systems used; and so on. As each of these factors gets decided, the range of possibilities for the building get narrower and narrower — but not much more so than in any conventional design process.At any point, the program “would also provide information about a lot of the things that are not yet defined,” essentially offering a menu of choices that could lead to a more environmentally friendly design, says Kirchain, who is a principal research scientist at MIT and co-director of the CSH, which supported the project.While designed particularly for reducing the climate impact of a building, the same tool could also be used to optimize a building for other criteria, such as simply to minimize cost, the researchers say.Getting in earlyThinking about issues such as the ultimate fate of a building at the end of its functional life tends to be “not in the same order of interest for the designing architect, when they first work on a design,” compared to more immediate factors such as how the building will look to the client, and meeting any particular functional requirements for the structure, Ulm says. But if the new LCA tools are integrated right into the design software they are using, then indications of how a given design choice can affect the outcome would be constantly available and able to easily influence choices even in small, subtle ways early in the process.By comparing the design process with and without the use of such tools, the researchers found that the overall greenhouse gas emissions associated with a building could be reduced by 75 percent “without a reduction in the flexibility of the design process,” Ulm says.Ulm compares it to indicators in a gym that provide feedback on how many calories are being burned at any point in an exercise regime, providing a constant incentive to improve results — without ever prescribing what exercises the person should do or how to do them.While the program is currently designed to evaluate relatively simple single-family homes — which represent the vast majority of living spaces in the U.S. — the team hopes to expand it to be able to work on much bigger residential or commercial buildings as well.At this point, the software the team designed is a standalone package, so “one of our tasks going forward is to actually transition to making it a plug-in to some of the software tools that are out there” for architectural design, says Kirchain.While there are many software tools available to help with evaluating a building’s environmental impact, Kirchain says, “we don’t see a lot of architects using these tools.” But that’s partly because these tend to be too prescriptive, he says, pointing toward an optimal design and constricting the designer’s choices. “Our theory is that any designer doesn’t want to be told that this is how the design must be. Their role is to design without undue constraints,” he says.

Lhoist North America recently acknowledged the shortage of drivers available for heavy-duty trucking, along with the exacerbating effects of higher freight volume demands, plus the Federal Motor Carrier Safety Administration’s enforcement of the electronic logging device mandate, limiting drivers’ hours of service.Customers can make the limited transportation pool more efficient, the lime and limestone producer notes, by: Placing orders as far in advance as possible to augment truck scheduling; being as flexible as possible with receiving hours; and, minimizing check in/check out process delays and allowing carriers to unload as quickly as possible.“We continue to work to expand our logistics capabilities by partnering with our existing carriers to be a ‘shipper of choice’ and by finding new carriers who can provide safe, reliable, and high quality delivery service to you,” the producer tells customers. “We are confident carriers are doing everything they can to recruit and retain drivers to help minimize the impact on all of our businesses. These actions include increasing wages, offering signing bonuses, developing more flexible driver schedules and minimizing weekend and holiday work.”

To the average layman, blockchain technology is synonymous with cryptocurrency and bitcoin – not that even above-average laypeople could likely pass a pop quiz on any of those terms. But Alpha Corporation Market Strategist Andrew Lindsey, who could write and grade that quiz, says it’s dangerous to confuse blockchain with its nefarious currency origins. And when he talks about the technology's promise for the AEC industry, he’s not just at the edge of his seat, he’s leaping out of it.Since spring, Andrew has been on the steering committee for the Construction Blockchain Consortium (CBC), an extension of University College London. Thus, the aforementioned seat from which he leaps is a front-row chair at the dramatic, disruptive performance of a lifetime: the collaborative convergence of new technologies, STEM leaders, policymakers, and the built environment.Andrew’s session at the Infrastructure Imperative conference Nov. 13-15 in Cleveland is titled “How Rapidly Changing Technology is Impacting Infrastructure Design and Construction.” Our interview with him this week is but an opening prelude to the exciting, real-life tale that’s unfolding real-time in our industry.Concrete Construction (CC): Would you mind breaking down blockchain to its simplest definition?Andrew: It's a digital ledger of transactions between two or more parties that is immutable, tamper-proof, decentralized, and encrypted.What you often see now in digital communications is a value exchange that reflects a value exchange happening outside the digital landscape. If I make a trade on the stock market, that’s not actually the trade that’s happening – that’s a cue on a digital interface that tells a bank to make that trade.That’s Web 2.0. And the people who hold the keys to that digital interface now control all the power. You’re seeing that with Google, with Facebook, with Verizon. Whoever controls the data flow controls everything.CC: How do you help people make the mental separation between blockchain and bitcoin?Andrew: Using blockchain interchangeably with cryptocurrency and bitcoin is very dangerous. The original use for bitcoin was for nefarious purposes [buying illegal goods or funding illegal activities], so now there’s a thought association that comes with it. That could be the reason the technology is delayed: Decision-makers may see it as a deviance tool rather than a high-utility streamlining tool.CC: So how exactly can blockchain help streamline building and infrastructure projects?Andrew: If you want to understand who holds what when and where, you can see a 30,000-foot view of everything that’s happened. It’s all time-stamped, can’t be touched or broken into, and irreversible. That’s the jump off point for construction applications.In the first level, we’re likely to see the value exchange of the ‘handover’ specifically – handing you my design specs, for example.One of the easiest ways for a claim to come up is over who held what when and who handed what over when. When you have a very clear snapshot of all of that information, you can see what would happen to claims. You’ll only be interpreting the why rather than the what, which is half the battle.Also, if you also look at supply chain management, the flow of materials, that is really big. In construction management, if you look at the cost estimating, scheduling, or other project controls, whoever can see what is where best has the best service.Right now, it’s done off a spreadsheet that says "X is going to arrive here within this timeframe with this level of error." But if you have an immediate, encrypted, and immutable ledger of the flow of items, you can identify exactly what is going to be where, when and you can reflect that in schedules, cost estimates, and, more broadly, phase engineering.This could be the kicker: If I can tell you better information than a major corporation, give a 100% more accurate snapshot, well now you’ve given the keys to a completely different party.That’s just Level 1 of this technology!CC: Will you cover Levels 2, 3, and 4 at Infrastructure Imperative? Andrew: Yes. When we get to 4, it’s a big but impactful pill to digest, which is exactly what this industry needs.CC: What are the obstacles blocking blockchain adoption in this industry?Andrew: Adoption is inevitable, but five things will slow it down:Technological innovation. To use this technology at scale, another level of technology is required. The real-time processing power isn’t there yet, but it’s coming.Regulation. It’s possible to use the technology independently, but then the value isn't there. The best case for using it is when everybody’s using it.Market disruption, the inflexion point at which this takes hold. When people say yes, we have to switch over to our neighbor’s technology because they’re the ones that are feeding us financially. And that takes time.Education. People must know how to use this thing if they’re going to be using it between parties.Social willingness. If people don’t want it they won’t use it. For this to work, multiple parties must commit to its use.CC: Andrew’s not only passionate and articulate about blockchain’s potency within the built environment – he told us he’s eager to channel the synergies of technology, STEM research leaders, AEC industry leaders, and educators toward one specific problem: the $46 billion gap in U.S. educational infrastructure. He ultimately envisions easier accessibility to resources for all K-12 students. Today, Andrew and his mother, Kate Lindsey, CEO of Alpha Corporation, are focused on their newly created International Education Infrastructure Alliance.Like blockchain itself, the future good of Andrew’s work is immutable. The opportunity to hear this inspiring thought leader in person should not be missed.

Houses can be made of wood, as they were in the past -- or of concrete, as they are today. To build for tomorrow, the two building methods are being combined: these hybrid structures, which contain both wood and concrete elements, are becoming increasingly popular in contemporary architecture.In the context of the National Resource Programme "Resource Wood" (NRP 66), Swiss researchers have now developed an even more radical approach to combining wood and concrete: they are fabricating a load-bearing concrete which itself consists largely of wood. In many blends, the volume fraction of the wood is over 50 percent.Cement-bonded wood products have been around for more than a hundred years. Yet previously they were used only for non-load-bearing purposes, such as insulation. Daia Zwicky, head of the Institute for Building and Environmental Technologies at the School of Engineering and Architecture of Fribourg, wondered whether it wasn't time for a more ambitious use of wood-based concrete.Floating concreteTogether with his team, Zwicky experimented with the content and granularity of the wood as well as diverse additives and subsequently subjected the various blends to rigorous tests. The main difference from classical concrete is that the gravel and sand content is replaced with finely ground wood. In other words, sawdust rather than small stones is mixed in with the cement. Thanks to the high wood content, the new building materials show good flame retardance and act as thermal insulation. "They weigh at most half of what normal concrete weighs -- the lightest of them even float!" says Zwicky. Moreover, as the materials are based largely on renewable resources, after dismantling they can be reused as a source of heat and electricity. The wood content can be burnt in waste incineration, although for everyday use it conforms to fire protection standards.Initial 1:1 stress tests show that the new wood-based concrete is also suitable for slab and wall elements and can provide a load-bearing function in construction. The process is also suited to prefabricated units. In this context, in particular, the Fribourg group would like to deepen their expertise through a broader range of tests. The researchers want to find out which wood-concrete composite is best for which applications, and how it can be produced efficiently."It will take several years before we see the first buildings in which lightweight concrete containing wood plays an integral role in the construction," says Zwicky. "The level of knowledge required for widespread application is still too limited."

Direct Air Capture (DAC) is a method of collecting carbon dioxide from the atmosphere at more diverse and distributed concentrations. DACs push air past a sorbent chemical which binds with CO2, effectively separating it from other molecules. Afterwards, it is unbound, purified, and concentrated for use in industrial applications. While cost for the process remains high, entrepreneurs are helping the technology mature in order to make it a more reliable means of reducing greenhouse gas emissions.The Healthy Climate Alliance (HCA) is using a prototype DAC that uses a resin-based sorbent which collects CO2 from the air and releases it when submerged in water. The seven-foot tall prototype has the capacity to pull 2-10 pounds of carbon a day. The HCA then sells the CO2 to Blue Planet Ltd., a construction company that creates carbon based building products for use in materials like concrete.

The American Concrete Institute announces the launch of a series of seminars hosted at ACI Headquarters in Farmington Hills, MI, USA, that will enable concrete industry professionals to receive valuable information on a variety of topics.The seminars will allow attendees to earn PDHs/CEUs, an increasing requirement to retain PE status. Highly recognized speakers will offer face-to-face interaction, and free resources and referencing tools will be distributed for use both during and after the seminar.The first seminar, “ACI 562: Assessment, Repair, and Rehabilitation of Existing Concrete Structures,” will be held October 30, 2018. The one-day seminar will help attendees learn how to use the ACI 562 code; learn about a design-basis code; and understand the different load combinations and reduction factors in ACI 562.Future public seminar topics include: Concrete Slabs-on-Ground; Troubleshooting Concrete Construction; and Troubleshooting Concrete Forming and Shoring. The seminars will be held at ACI Headquarters, in Farmington Hills, MI, USA.

Call it a wish list or, if you’re feeling jaded, the biggest insurance policy on projects today – but what if the increasingly popular 100-year service life requirement is actually not that accurate to be “guaranteed”?The concept has brought additional focus to the long-term performance of infrastructure, but the AEC industry hasn’t defined “100-year service life” or given engineers and designers consensus-based standards for achieving that goal. It’s important that an appropriate tool is developed with industrywide participation and agreement.Such is the message of Oscar Antommattei, MS, PE, FACI, a senior concrete engineer and engineering manager at Kiewit , who explains his position here. He’ll expound more fully at the Infrastructure Imperative Conference Nov. 13 - 15 in Cleveland.Concrete Construction (CC): What’s the sticking point vis-à-vis the 100-year service life concept?Oscar: Everyone has a different idea of what “100-year project” means. Consensus-based standards or guidelines don’t exist to determine what’s going to be used for estimating, designing, and building a project like that. That’s the challenge.Is it true? Is it not true? There’s no way to answer these questions without a standardized way to verify more accurately the certainty of those predictions. And from a more practical standpoint, nobody who’s alive today is going to be here in 100 years.CC: If there’s no uniform code for defining and achieving 100-year service life, doesn’t that make bidding difficult (to say the least)?Oscar: Absolutely. You might be a builder who knows too much, and that can be a disadvantage.Why? Because there’s no standard. No rules. And you know more about what will be involved.The other guy is going to say, “I can do it this way, and I can meet, for example, the International Federation for Structural Concrete (FIB).” But the owners developing these specifications might not know the European code well enough to tell you where they want you to be. Most people in North America are more familiar with American Concrete Institute (ACI) standards, but ACI hasn’t developed a comprehensive standard.A project specification may say 100-year service life, but what does that mean?! It’s like saying, “I want blue.” One bid gives you baby blue; another, navy blue. “Hey – all you said was ‘blue.’”At the end of the day, we’re all working from a different playbook.CC: Isn’t FIB – the code developed in Europe – a reasonable place from which to base 100-year design?Oscar: It’s not that simple. Extrapolating European codes in North America may not be workable or applicable for all cases. Projects and industry views are so different, from the way they’re procured, designed and built to the social environment. Durability expectations aren’t necessarily the same, and that’s very important.Some people are trying to use FIB, as well as other analytical and modeling proprietary concepts, here; but we need to determine if or what components of an approach are relevant or not in the U.S. market. There are many different views and considerations to ensure the right approach is implemented for long-term durability assessments in North America.The other thing to think about is the way we procure projects in North America. While a value-based approach is being used more frequently, a traditional low-cost approach isn’t well-suited for long-term performance such as 100-year service life.CC: If there’s no consensus-based code and no true verification – and yet these things are written into contracts – are we stockpiling trouble for future generations?Oscar: It depends on how much credence is put into 100-year performance. The industry has long been building work that has a long life—40, 50, 60 years, sometimes even longer. It’s putting the label and expectation of 100 years on it that causes problems, especially without a consensus-based standard.The industry just keeps procuring projects without a standardized process or standardized verification on what exactly 100 years means. There have to be standards that clearly describe the approach needed to achieve this, or at least to have a level playing field.The good thing is that people are discussing it.CC: Is anyone moving the ball to get these much-needed standards created for the U.S.?Oscar: Many organizations have published papers about 100-year performance, but those aren’t consensus documents. So far, it’s just a wish list from a single perspective. You don’t see in-depth involvement from design and construction practitioners or from concrete producers or materials manufacturers, the people who are going to implement all that theoretical knowledge.I’m co-chair of a recently established ACI task force that will start developing standards for design and construction of durable structures. We hope to provide tools that close the knowledge gap and establish a more consistent approach to the durability and service-life concepts.CC: If ever there was a task that needed force, I’d say it’s this one!Oscar: Yes, and at least there will be a level plane for everyone so you can see where the consensus basis is and work from there.CC: Can’t today’s sophisticated technologies help with the accuracy of predicting 100-year longevity?Oscar: Many researchers are pushing technology to a level where you start getting some predictions. However, accuracy must be verified and calibrated to ensure you can do it consistently and reliably. Who can say something will last 100 years – you’d have to wait 100 years to check. Without parameters in place, uncertainty will exist.You can put together three different models and they’re going to predict three different things. How is that even acceptable?! Which is the best one to stand behind? At this point, no one knows. A lot of judgement is required without any standardization.Some owners see the most expensive and difficult proposal and say, “Oh, that’s the one.” But you don’t know that. It doesn’t mean anything until there is consensus and it’s been standardized and verified.As engineers and practitioners, we need to make sure we have the right tools and technologies available to everyone. We must look at the big picture and not go into the weeds of 100.2 years versus 98 years, for example. Current tools aren’t that accurate or exact to establish such specific values in a reliable way.CC: What does your crystal ball say about the future of 100-year durability requirements?Oscar: Consensus is coming. Hopefully, in 20 years, we’ll have different procuring practices and different ways of estimating and designing work.The building-constructing work is going to change, too. You’re going to have to have more robust quality-control practices.There needs to be more effort in the pre-bid period, too. Testing procedures take a long time – currently, there’s no way you can procure projects without getting into some type of testing pre-bid so you can understand what you’ve got and design for it.Eventually, you’ll be able to guarantee your long-term performance with a sounder approach that is backed by more reliable data and not just subjective conjecture.

The world-class education program will include 180+ sessions including seminars, 40+ industry trainings & skill-building events, along with more hands-on training opportunities and interactive workshops than ever before.World of Concrete attendee registration has officially opened and expectations are this will be the largest WOC event in over a decade. With a strong economy and a viable & active construction sector, the concrete & masonry industries will converge in Las Vegas at the Las Vegas Convention Center January 22-25; Seminars 21-25, for this highly-anticipated annual event.With six months remaining until WOC 2019, organizers are anticipating significant growth over World of Concrete 2018–which was the largest event in nine years, with 58,000 registered professionals featuring 1,564 leading-industry suppliers exhibiting across more than 746,000 net square feet of space.“There are some very positive changes to the show floor for 2019. We have moved the Masonry area to Central Hall, and Technology to the North Hall, to accommodate both of these growing sectors of our industry. We look forward to filling what is left in available booth space throughout the fall, culminating in another action-packed event for our attendees. We also have several new events in the works, and a multi-day expansion of the Masonry Madness events happening in the Bronze Lot,” said Kevin Archibald, Show Manager.QUICK LINKS WITH THE LATEST SHOW INFO: EDUCATION I EVENTS I PRICING & SHOW HOURS I HOTEL & TRAVELThe world-class education program will include 180+ sessions including 90-minute seminars, 3-hour seminars, 40+ industry trainings & skill-building events, along with more hands-on training opportunities and interactive workshops than ever before. The full WOC 2019 Education program is now available online at www.worldofconcrete.com/en/education.html.Recently updated on the WOC website are all of the events happening in the Bronze Lot, Breakfasts, Luncheons and Special Events & Tours unique to WOC, an updated 2019 Floor Plan (including exhibitors and products listings) and pricing/registration information.World of Concrete 2019, taking place January 22-25; Seminars 21-25, at the Las Vegas Convention Center.

The National Center for Education and Research on Corrosion and Materials Performance (NCERCAMP), is hosting a two-day event on sustainable concrete Thursday, October 11 and Firday, October 12 at the University's Engineering Research Center.Low additive high early-strength concrete is becoming more popular, but what is it?Concrete is a versatile building material that enjoys excellent thermal mass and varied design options but can require significant amounts of noncementitious materials carrying a high carbon footprint for maintenance. Low additive high early strength concrete relies on natural solutions and chemistry to produce more resilient concrete with less impact on our environment.Smart micro-encapsulated corrosion inhibitors help guard against concrete corrosion, specifically in areas where steel rebar makes contact with the concrete matrix. This system of limiting corrosion of concrete will be explained in a one hour lecture on October 12 by NCERCAMP’s own Dr. David M. Bastidas.During the two day event, live demonstrations of another natural concrete, reactive copolymerizing solids (RCS), will take place outside on campus.

This webinar will present the background information and basic design rules for the strut-and-tie method prescribed in the ACI 318-14 Building Code Requirements for Structural Concrete. Guidance will be given for the development of a strut-and-tie model (truss model) to be used for analysis and design of either D-regions (disturbed regions) within a member or the entire member. Design rules and strength limits will be given for the elements of a strut-and-tie model, namely the struts, ties and nodes. An example is included to show the steps required to design a member using the strut-and-tie method.

BASF now provides third-party verified Manufacturer Inventory Reports for all its admixture and fiber products to meet the requirements of the LEED v4 Building Product Disclosure and Optimization – Material Ingredients, Option 1 credit.In 2017, BASF was the first admixture company to provide third-party LEED v4-compliant Manufacturer Inventory Reports through GreenCircle LLC. The environmental consultant company audited and verified that BASF’s internal Product Compliance Management System assesses the hazards of all the ingredients that make up the product, including impurities. This verification provides BASF with the capabilities for certifying its entire portfolio of Master Builders Solutions products.BASF offers a wide range of sustainability tools and service solutions to support the construction industry. These include externally verified, ISO compliant declarations for concrete products (Environmental Product Declarations, EPD); a comparative life cycle assessment methodology that balances the cost and environmental impacts of alternative products, processes and technologies (Eco-Efficiency Analysis, EEA); and the Green Sense concrete advanced mixture optimization service to produce high quality, environmentally-preferable concrete. These value-added service solutions are available to all BASF customers.“With the GreenCircle Certification, we ensure an independent authentication of our company’s product sustainability claims and help architects and design engineers make educated product selection decisions during the research and design phase of a project. Environmentally-preferred products are truly changing how construction material selection decisions are being made”, says David R. Green, Manager of Applied Sustainability for BASF Construction Chemicals. “Demand for transparent information on products and solutions in all business sectors will continue to grow.”

The Safety and Risk Management Council (SRMC) of the American Society of Concrete Contractors (ASCC), is pleased to announce that Tim Manherz, Senior Vice President of Operations at TAS Commercial Concrete, is this year’s recipient of the ASCC Member Owner Safety Award, presented Sept. 20 at the ASCC Annual Conference. The award recognizes one owner/executive of a contractor member company who provides leadership that creates a best-in-class safety culture.Manherz received a B.S. in construction from Arizona State University where he graduated with honors and was named “Outstanding Graduate” of his class. He is a member of the ASCC board of directors and current president of the Tilt-Up Concrete Association.TAS works over 3,000,000 man hours annually. For the past three years they have had an RIR average of 1.9 and an average EMR of 0.45.In nominating Tim, TAS employees wrote, “Safety has always been priority for TAS management, with Tim as one of the TAS Safety Team’s biggest champions. Tim is the live wire conducting the energy that binds production and safety into a unified force at TAS, now operating in Houston, Dallas, and several other cities in central Texas. His close work with, and mentorship to the Safety Team, ensures a constant line of communication between production and safety, thus facilitating a unity of action that ultimately benefits every TAS employee.”This award is in keeping with Goal #1 of the ASCC Strategic Plan: Increase the Number of Contractor Member Owners Who Truly Demonstrate a Personal Commitment to Safety.“Strong safety cultures thrive in organizations where leaders take an active role,” says Mike Schneider, SRMC council director. “Contractor member owners that understand this know that building a true safety culture begins and ends with them: the priorities they set, the choices they make and their expectations of others. It requires effort and commitment from the top, but employees will tell you that it makes a difference.”SRMC is a specialty council dedicated to making ASCC contractors the safest in the industry. The board consists of safety and insurance professionals from all aspects of the concrete contracting industry. Council activities include publication development, review and monitoring of ASCC events and materials for safety compliance, member education, a safety awards program, and a safety/insurance hotline.The ASCC is a non-profit organization dedicated to enhancing the capabilities of those who build with concrete, and to providing them a unified voice in the construction industry. Members include concrete contracting firms, manufacturers, suppliers and others interested in the concrete industry, such as architects, specifiers and distributors. There are approximately 730 member companies in the U.S. and 11 foreign countries.

The Oklahoma/Arkansas chapter of the American Concrete Paving Association (ACPA) has pledged $500,000 in support of further research into concrete paving to the Department of Civil Engineering at the University of Arkansas.Concrete pavement advances have become more complex, according to Cameron Murray, a civil engineering assistant professor at the University of Arkansas. The study will fund concrete pavement initiatives, research, and related activities for the department.

A sound-proof installation on display at the Karolinska Institutet in Sweden was constructed from translucent concrete panels made by squeezing High-Performance Concrete between two sheets of bubble wrap. The material's 1 million membrane-perforations trap noise and its 262,500 cavities disperse high-pitch sound.

Pessimism isn’t in my vocabulary, and so I really don’t like pessimists, those who run through the streets screaming doom and gloom, claiming the world is coming to an end.This has been a hard few days in the stock market, but the causes of this pullback that has rattled many are very self-evident: the market was overbought, valuations have been on the high side, and we are FINALLY seeing fixed income yields rising, an absolute positive for those who are retired or are living on fixed incomes. This is a natural happening in the sawtooth movement of the stock market going back to the inception of indexes more than 100 years ago. This no doubt has a lingering effect on consumer confidence and overall sentiment, my all-time favorite indicator of whether the economy is still pointed uphill.The momentum behind consumer confidence is so great right now, I predict the stock market rout of the last few days won’t even move the sentiment needle. Consumer confidence hit an 18-year high in September, a positive indicator for spending going into the holiday shopping season, as robust job growth and a strong economic outlook bolstered Americans’ expectations for the future.The Conference Board, a private research group, recently reported its index of consumer confidence rose to 138.4, up from 134.7 in August, the highest level since September 2000, which represented the late stages of the 1990s technology boom. An index reading of 100 represents how households saw the economy in 1985. The report came on the heels of a separate University of Michigan survey that said sentiment jumped in early September to the second-highest level since 2004, behind only the reading in March of this year.Economists have voiced concerns about trade and tariffs as risks to economic growth over the next 12 months. For consumers, however, the issue isn’t registering. Lofty consumer sentiment bodes well for economic growth in the third quarter, now behind us and just awaiting the results of the quarter’s economic activity. Economists are predicting that gross domestic product expanded at between a 3.3% and 4.4% annual pace in the third quarter. This comes on the heels of a robust 4.2% annual rate in the second quarter, largely because of the best consumer spending in nearly four years, according to a report released by the Commerce Department in late August.Now back to the pessimists. Because housing looms so large in the overall construction sector, it appears the only soft spot in an otherwise robust economy is housing. Home price gains slowed in July, according to the S&P CoreLogic Case-Shiller National Home Price Index. This drives no less than a dozen headlines I have read that predict doom and gloom for construction, even though all other non-housing construction has been strong through the first three quarters of 2018.The conference board asks households how they feel about the present situation and about their outlook for the future. In previous reports, present-situation readings had been strong, while future outlooks were lagging. Now expectations for the future are heading up, too. The index tracking expectations for the future rose to 115.3 this month from 109.3 last month. Most respondents, 42.5%, expect stock prices to continue rising over the next 12 months, while 35.1% expect them to hold steady and 22.4% expect a decline. To be sure, these figures predate the rout of the last few days, so it will be interesting to read next month’s numbers. And consumers are also relatively upbeat about their employment prospects; in September, 45.7% said jobs were plentiful, up from 42.3% in August.I remain upbeat about housing’s prospect. Affordability, labor constraints, and land development are hurdles that need to be overcome, and I predict they will – the housing market has faced these challenges in the past, and managed to navigate through them successfully. In the meantime, the rest of the construction landscape looks strong, and the current mood of positive sentiment with respect to the rest of the economy will keep driving us forward.

he restoration of the Sheaf fountain in Palekh, Russia involved changing the original rectangular shape of the structure to a round shape that includes mounted underwater lights. The parapets, or barriers that extend around the base of the fountain, were 3D printed using structural and geopolymer concretes, gypsum, clay, use mixtures with mineral additives and fiberglass. Additive Manufacturing Technologies (AMT) developed the construction printers, capable of manufacturing concrete structures up to almost 600 square feet.

The American Concrete Institute (ACI) presented the "Excellence Award," their highest honor, to Viaduct Over River Almonte in Garrovillas de Alconétar, Cáceres, Extremadura, Spain. This award is given annually to one project that demonstrates excellence in concrete innovation and technology and stands out above all other entries.A new high-speed rail line is under construction between Madrid and the Extremadura, a western Spanish region bordering Portugal. The line will cross over the River Almonte on a 3270 foot long viaduct—a concrete arch bridge with a main span of 1260 feet. Designed to carry 218 mph rail traffic, the viaduct had to meet rigorous dynamic, serviceability, and safety criteria; and it required complex, staged calculations based on nonlinear material and nonlinear geometry behaviors. Nevertheless, it is aerodynamic and slender, largely due to key design features, including a four-legged arch configuration; 11,603 psi high-performance concrete; an efficient erection method, with temporary towers and stays; and an innovative monitoring system.The viaduct’s 1260 foot main span makes it the largest railway bridge in Spain and the world’s largest concrete arch bridge for high-speed rail service. Its design combines structural efficiency, out-of-plane stability, improved response against cross wind effects, and aesthetics. The design is also environmentally friendly, as the bridge comprises durable materials, has been designed for expedient maintenance, and will include a bespoke barrier that will force birds to soar upward and above the overhead mast line. The bridge arch comprises high-performance, self-consolidating concrete. The complex erection procedure required the development of singular construction devices. The bridge was constructed using a ground-breaking instrumentation and monitoring system that provides information regarding the behavior of the structure during construction and service.The ACI Excellence in Concrete Construction Awards were created to honor the visions of the most creative projects in the concrete industry, while providing a platform to recognize concrete innovation, technology, and excellence across the globe. To be eligible for participation in the Excellence Awards, projects needed to be winners at a local ACI Chapter level and submitted by that chapter or chosen by one of ACI’s International Partners.An independent panel of esteemed industry professionals judged projects and selected winners based on architectural and engineering merit, creativity, innovative construction techniques or solutions, innovative use of materials, ingenuity, sustainability, resilience, and functionality.Additional winning projects were selected from among several possible categories, and included:Decorative ConcreteFirst Place: Roofing of the Montpellier-South of France TGV Station in Montpellier, Herault, FranceSecond Place: Water Garden in Santa Monica, Calif.High-Rise BuildingsFirst Place: Reston Station OB1 Tower in Reston, Va.Second Place: Nexus Shopping and Business in Setor Marista, Goiânia, BrazilInfrastructureFirst Place: Viaduct Over River Almonte in Garrovillas de Alconétar, Cáceres, Extremadura, SpainSecond Place: Viroflay Underground Train Station – in Meudon, Hauts-de-Seine, FranceLow-Rise BuildingsFirst Place: University of Iowa Visual Arts Building, in Iowa City, IowaSecond Place: Design & Build of South Marina Yacht Club at Lusail (BP15) in Doha, QatarMid-Rise BuildingsFirst Place: 1200 Intrepid Avenue in Philadelphia, Penn.Second Place: Royal Alberta Museum in Edmonton, Alberta, CanadaRepair & RestorationFirst Place: Provo City Center Temple in Provo, UtahSecond Place: Ford Theaters Off Season Improvements Phase 2 & 3 in Hollywood, Calif.The winning project details can be found at ACIExcellence.org. Entries for the 2019 Excellence in Concrete Construction Awards are being accepted now through April 2, 2019.

On Sept. 25, the Construction Industry Alliance for Suicide Prevention (Alliance) held its first strategic planning session in Washington, D.C. Formed two years ago by the Construction Financial Management Association (CFMA), the mission of the Alliance is to provide and disseminate information and resources for suicide prevention and mental health promotion in construction.During strategic planning, nearly 30 representatives from 17 Alliance member organizations and the Board of Trustees created a framework for the future by forming governance, fundraising, education, and marketing task forces. The Board of Trustees will be led by Chairman Michelle Walker (Specialized Services Co.), Vice Chairman Keith Vitkovich (United Union of Roofers, Waterproofers & Allied Workers), Treasurer Brad Robinson (Lendlease), and Secretary Steve Tenney (Story Construction Co.), and includes Greg Sizemore (Associated Builders and Contractors), Edmund McCombs (Lendlease), and Tracey Fenolio (FCL Builders).According to Chairman Michelle Walker, “The action-oriented outcome and collaboration among all who were present at the strategic planning meeting clearly demonstrated the construction industry’s ability to come together to create great things. With the engagement and commitment of Alliance members on focused task forces, we are well on our way to effectively equipping companies to reduce the risk of suicide and impact of mental illness in construction.”This meeting coincided with National Suicide Prevention Month and a flurry of supportive activity throughout the construction industry. On Sept. 13, 2018, FCL Builders hosted its third annual Charity Casino Night, and nearly $144,000 was generously donated to further the efforts of the Alliance.In addition, FCL Builders and Lendlease have both joined as contractor members of the Alliance. As noted by Andrew Council, Managing Director of the Americas Construction business, “At Lendlease, we’ve prioritized mental wellbeing and suicide prevention within our company and safety culture. By remaining diligent, adaptable, and proactive in our approach, we are excited to work alongside the Alliance to make strides in mental health and to extend our reach and impact in the industry.”Of significant importance has been the recent addition of North America’s Building Trades Unions (NABTU) as an Alliance member. NABTU is an alliance of 14 national and international unions that collectively represent three million workers across all aspects of the building trades, including Laborers’ International Union of North America (LIUNA), International Brotherhood of Electrical Workers (IBEW), United Association – Union of Plumbers, Fitters, Welders and Service Techs (UA), and United Union of Roofers, Waterproofers & Allied Workers. The support of NABTU will greatly assist the Alliance in achieving its mission.CFMA President & CEO Stuart Binstock added, “We are humbled by the industry’s strong support of this initiative to save the lives of our most valued resources – our human capital. CFMA will remain as committed as ever to this cause and continue to champion the efforts of the Alliance and the astounding work, present and future, of its members who represent all aspects of the construction industry.”

Boston Dynamics has engineered a small robot dog which may be the solution to construction labor shortages. SpotMini is a little over 66 pounds, agile, flexible, and all-electric. One charge is good for 90 minutes of surveying for a project, handling objects using perception sensors, and mobile navigation and manipulation via its camera and mechanical arm. The company is on track to produce 1,000 SpotMini robots by the end of 2019.Some industry respondents to a survey from the Associated General Contractors of America and Autodesk this fall indicated they are introducing virtual construction, offsite prefabrication, BIM, drones, GPS, laser-guided equipment and 3D printing to help ease labor shortages.

Secolo is a high-quality dining facility located in the financial and retail hub of Sydney, Australia. This project was designed and specified by the client's architect. The primary challenges for contractor Contract by Design, were logistics. The project had to be completed within a tight schedule, the time frame needed to allow the business to re-open quickly, with minimal delays.An additional challenge was the projects location. Being in the center of the city, materials had to be delivered outside of normal work hours to minimize risk and inconvenience to other tenants and the public.Consequently, being poured in-situ, this build consisted of some on-site construction of formwork and some factory pre-build. The pre-builds were mounted onto trolleys, wheeled into place, and secured. Concrete was also poured outside of normal work hours to again minimize risk and inconvenience. In total, 375 square feet of off-form and trowel finished off-white concrete was polished using KGS Fledis pads and TRx sealer.The project has been very well received by the owners and staff. During a recent visit, they each commented on the public reaction. The common theme is that they cannot help but touch, feel, and even stroke the concrete.

Stances on infrastructure funding and immigration are just some of the issues that may impact the construction industry depending on the outcome of this year's midterm elections. In regards to infrastructure, the federal gas tax hasn't increased since 1993 and the Highway Trust Fund, which supports the nations roads bridges and surface transportation projects, is nearly empty. An increase in the tax has had some bipartisan support in Congress, though many lawmakers say they don't want to add another tax to the working class.Conflicts over construction of the U.S.-Mexico border wall may affect the industry in several ways. If constructed, the $22 billion project would create up to tens of thousands of jobs. Even so, this might deter or prevent the much needed labor of immigrant workers, which would be a blow to the already suffering U.S. construction labor pool. Groups like the Associated General Contractors of America have stepped in to request a temporary guest worker program that would give skilled workers abroad permission to work in the U.S.

The Mead School District in Spokane, Washington was new to polished concrete. Early in the design process, the district desired to install polished concrete floors with aspirations to create a floor that was unique. The design team reached out to Contractor Cameron-Reilly (CR) for assistance with the polished concrete design. The design team and CR visited various CR polished projects around the pacific northwest for visual inspiration; projects ranged from standard aggregate exposure to full terrazzo rock and glass seeded floors. Once the desired look of the floor was agreed on, CR guided the design team with a solid road map of how to write the polished concrete specifications to capture the appropriate tools, materials, contractor experience, and building sequence.The final polished concrete design included a four color combination of glass. Unique color glass combinations where broken into four main areas: the corridors, art and science rooms, main common/cafeteria areas, and hallways. Early in the construction process, CR worked closely with Garco Construction to sequence the polished floor construction. The first important detail was to sequence the floor pours within the building footprint, holding out the polished floors until later in the construction process. Another important detail was strategically placing the polished concrete construction joints one foot beyond designated wall lines. The schedule allowed for the grind and polish to be complete prior to erection of interior walls. This enabled large polishing equipment to over-grind underneath finished walls, ensuring a consistent look and eliminations/minimization of hand work.Almost eight tons of colored glass was organized in four color combinations. Great care was taken to balance the color gradations using a small concrete mixer and large plastic holding drums. Each concrete pour was precisely measured and organized to ensure the correct amount of glass was seeded on top of the concrete as it was finished into the surface. Great skill from the concrete finishers was needed to understand the timing of seeding the glass atop the freshly placed concrete.A Somero laser screed was used to ensure a flat and level surface along with power trowels utilizing steel pans to further cut the concrete smooth and properly seat the glass. A Ra meter was used for the grind and polish process. This newer technology measures real numbers and data to identify the state of the floor and determine the next step to follow. Concrete slurry was managed utilizing a custom made vacuum truck with 300 feet of hose and vacuum wands removing the material right behind the polish machines. The custom truck removes slurry quickly and safely from the site. Skudo MT high quality floor protection was utilized to properly protect the final polished floor.The planning in design, pre-construction, and attention to detail through the construction process made the project successful. All of the initial goals were met, all of the fine details were achieved. The polished concrete floors were loudly championed as the focal point of the school.

Mexico Beach, Florida, on the shore of the Gulf of Mexico, saw devastating destruction after Hurricane Michael ripped through the town. The Category 4 hurricane destroyed most homes along the shore.Among the few still standing is an elevated house called the "Sand Palace" a reinforced concrete home that stands on elevated tall pilings, which allow storm surges to pass underneath. Breakaway siding that tears free without causing further damage to the concrete structure, was also implemented. The owners foresee only a month of cleanup and repair from minor water damage and a cracked shower window. The "Sand Palace" was designed to withstand winds far stronger than Florida building codes require for homes along the coast.

Aquajet Systems AB, manufacturer of hydrodemolition equipment recently acquired by Brokk AB, will be launching the Ergo System for the first time in the U.S. The robot offers four times the power of a hand lance in a compact footprint that contractors can easily move around the jobsite. It is ideal for work on floors, walls and ceilings.Aquajet will showcase the Ergo System in booth C4249 at World of Concrete 2019 in Las Vegas.`The Ergo System incorporates: the controller unit, which powers and controls the hydraulics, the Ergo Power Head, which manipulates the high pressure lance, and either the spine or the climber, unique systems used to support and maneuver the power head, based on project needs. The climber attaches to any standard scaffolding pipes and robotically moves along it to deliver powerful hydrodemolition forces for vertical concrete removal and repair, such as high-rise construction.The system exerts 1,000 newtons of reaction force, which is about half of the force employed by Aquajet’s largest hydrodemolition robot, the Aqua Cutter 710V. The robot can handle higher volumes of water, as much as four times greater reaction force than a human operator with a hand lance. This means the machine can remove concrete faster and easier.Hydrodemolition robots, such as the Ergo System, remove concrete to a preset depth consistently. Alternatively, a hand lance will likely leave inconsistent depths due to being held by an operator. This means contractors may have to do another pass with handheld breakers to even out the surface.“The Ergo System is the perfect package for a contractor looking to break into hydrodemolition or to expand their business,” says Roger Simonsson, Aquajet Systems Managing Director. “Beyond its robotic intelligent sensing controls — which help to keep workers out of harm’s way — the system offers minimal maintenance, and costs less than a third of a full-size robot. It’s an affordable option for contractors.”Contractors can easily move the 271-pound (123-kilogram) Ergo Controller unit around the jobsite and over soft or rough surfaces due to the wide wheels and low ground pressure. At just 44 inches tall and 17 inches wide, the Ergo transports easily on a pallet. Additionally, the system is also service friendly with hydraulic hose multiconnectors that are 100 percent sealed from moisture to virtually eliminate the risk of leaks during transportation.The Ergo System requires a high-pressure pump to operate. Aquajet offers a compact Power Pack ideal for the purpose, featuring a high-pressure Hammelmann pump, diesel engine and an integrated control system.

Sand and gravel from riverbeds and beaches is in high demand as the need to create concrete for construction continues to increase. Sand from coastal areas is preferred for its coarse grit. According to the Organization for Economic Co-operation and Development, 27 billion tons of sand and gravel are used for construction each year, with that number set to double by 2060.The decimation of sand from beaches and rivers has the potential to be environmentally detrimental to coasts. Scientists are now working to reduce the amount of raw materials used in creating concrete and other construction materials. One material being studied is plastic, which may be able to replace up to 10% of the sand used in concrete without affecting its integrity.

If your gut says construction could be so much more profitable if only the industry conformed to higher levels of productivity, kudos to your intuition!A recent analysis by the research arm of worldwide management consultants McKinsey & Company confirms your hunch and explains why productivity is notoriously and consistently poor. But the question of how to invert the downward trajectory has remained more or less unanswered – until now. “Reinventing Construction” identifies seven strategies that, if executed collectively, in unison across the sector, could put $1.6 trillion back into the global economy by increasing productivity 50% to 60%.On Nov. 13-15, the Infrastructure Imperative conference welcomes Corey Hopper, a consultant in McKinsey’s New York office, to break down these seven essentials. Because winning any battle requires knowing the enemy, Corey will also underscore barriers to change and how only true collaboration will overcome them.Our industry’s malaise can be traced to several root causes: “Construction is highly fragmented: Contracts have mismatches in risk allocations and rewards; inexperienced owners find it hard to navigate an opaque marketplace,” reads the report’s summary. “The industry is extensively regulated and depends highly on public-sector demand; informality and sometimes corruption distort the market. The result is poor project management and execution, insufficient skills, inadequate design processes, and underinvestment in skills development, R&D, and innovation.”The fix lies in:· Reshaping regulation· Rewiring the contractual framework to reshape industry dynamics· Rethinking design and engineering processes· Improving procurement and supply-chain management· Improving on-site execution· Infusing digital technology, new materials, and advanced automation· Re-skilling the workforce.Although concurrent implementation of all seven strategies is the path to successful turnaround, a couple deserve priority when a firm is ready to get serious about reform.“When applied comprehensively and efficiently, technology can reduce overall project costs significantly,” Corey says. “For people in the engineering and construction space, this rapid transformation is critical. After technology, on-site execution has great potential impact. We also see big opportunity in procurement and supply management as well as capability building.”Corey’s presentation will reveal which half of the construction sector trails vis-à-vis productivity and growth, and whose participation is vitally needed for stakeholders at all levels to be rewarded.Review the whole conference schedule and reserve your seat at the Infrastructure Imperative in Cleveland today – changing the thinking precedes changing the productivity at your organization, and getting your head around the basic strategies will happen here. Take action soon – space is filling fast in these final weeks.

With ever evolving technology, the construction industry has long caught up and recognised the need for integrated systems and construction management software to stay competitive and to support their business goals. But how do you replace a legacy system with new software without losing data and without generating chaos? More importantly, how to choose the right software for your contracting business?Construction management comes with a lot of challenges for contractors because they have to deal with a wide variety of tasks, such as overseeing subcontractors, materials and equipment, job costing and budgets, reporting on progress, inconsistent timelines and much more. Hence the need for advanced software to simplify and manage all kinds of workflows and tasks.But how can contractors find construction management software that is suitable for their business? Implementation of technology is expensive and choosing the wrong system could lead to major issues in the long run.Before selecting construction software for your business, you need to understand your business needs, challenges and goals. Mapping out your internal and external processes will help you understand the pain points and bottlenecks in your operations. How connected are your office employees, project teams and field crews? Where do delays typically occur in your processes?Giving thought to all these questions helps you eliminate issues and assists you in choosing a software that supports your organization in making processes more efficient and effective.Here are five simple steps to assist you in choosing the right software.1. Research software featuresA construction software might have excellent tools to support an individual’s work, but what features exist that allow you to share and collaborate with your team or various teams within your company and potentially even with outside stakeholders.The software you choose should be collaboration-friendly in a way that meets your needs. A good way of going about it is to test-drive a construction software’s collaboration features with a small group of colleagues in your team.Evaluating a software’s features, flexibility and support services are vital aspects to consider in the research phase. Firstly, you should visit the software provider’s website to get an overview of the software capabilities. Before you get in touch with the software provider, you should look at reviews or even better talk to other companies who are using the software already. Consider talking to construction software consultants independent from the software provider company. They have the necessary experience and can help you find a solution that is a good fit with your contracting business.There are many stand-alone solutions out there that support a specific task, such as job cost accounting, estimating, bid management, equipment management and much more. However, ideally you want to find integrated software that covers all those areas.2. Calculate and justify the cost"The biggest mistake you can make with productivity software is to add five minutes of extra work to each member of your team to save you five minutes."- Paul Cothenet, CTO at MadKudo.The cost and expenditure on a new software or integrated system is almost never justified in the short-term because it takes time to implement, teach team members how to use it and configure it to suit your company.Leaving short-term cost justification aside, what is more important is whether a new system is going to be justified in the long-run. The main question is whether the software is assisting your company in accomplishing tasks in a more efficient and effective way. Essentially, ask yourself whether the software is saving you time. The last thing you want is to make things more complicated than they already are. In the long-run the software needs to pay for itself and ideally support the processes within your company to improve your bottom-line.3. Compare different construction software and try alternativesResearching the best software for your business takes a lot of time. Sales people only tell you how awesome their system is and more often than not the flaws of their technology are not revealed until later on when you are stuck in a contract. Therefore, doing thorough research and comparing different systems and capabilities are very important. Don’t jump the gun in making your decision. Essentially, you need to get a deep understanding of the software and its capabilities. Get the software company to demo the system and prepare lots of questions to ask. Request a trial of the software for 1-3 months so that you and your colleagues can play around with it and to identify any potential issues. Approaching your evaluation phase of the software as described above will reveal the level and quality of support you can expect from the software provider.It is advisable to spend a considerable amount of time researching what systems are out there and narrow your choice down to three favourite systems. Then find out as much as you can about each. Compare those three systems with pros and cons.4. Get feedback from your teamWill my team be able to use the software? Does it solve their problems? Will it make their lives easier? Do they understand how to use it? What training is needed?Obviously you can enforce new software with a top down approach but it doesn’t come without risks. A better way of going about it is the bottom up approach. Engage your team in the research of the best construction management software, after all, they’re the ones using it.Assuming you can get access to a trial software solution for each team member, the first thing you want to do is organize a training session so that everyone can learn how to use the system. Prepare a set of fictional tasks each team member needs to complete with the trial software solution and last but not least prepare a questionnaire with specific questions to pinpoint whether the software makes their life easier.5. Prepare your implementation planImplementing a new software and making the most of it is a big challenge. It is highly recommended to create a detailed plan and strategy on how the new software will be rolled out across your contracting business and the various teams.Even if your team is tech-savvy, it might take them quite some time to get used to the new system and how they can integrate it into their daily workflow.Despite of having a dedicated account manager and ongoing support from the software provider company, you might want to consider assistance from a specialized construction software consulting company.Most important things to consider for the implementation:Configuration of the softwareData transfer from your previous systemIntegration of other systems that need to talk to your new softwareTraining for team members on using the softwareYour implementation plan should contain an overview of the system, a detailed description of major tasks involved in the implementation and resources needed to support the implementation. It should also give some consideration to hardware, materials, personnel requirements and resources.Take your time to find the right construction management software solution for your business. There are tremendous implications if you don’t do thorough research and testing before you enter a contract with the software provider. Choosing the wrong software can not only create tremendous costs, but more importantly it will frustrate your staff. If you follow the five steps outlined in this article you should be able to make an informed decision about the software you’re going to implement.

In my last column, I wrote how consumer confidence in the face of recent stock market swings bodes well for the U.S. economy. Now, Moody’s Investor Service has also spoken – and agrees. Moody’s analyses of opinions on everything from global outlooks to carefully vetted, deep-dive research on individual companies produce a ratings system that’s the gold standard of the global financial industry. The firm’s recently released forecast for the global construction economy confirms what the average consumer already knows: The economy continues to show unfaltering signs of strength, and that strength is evident throughout the world.Some might think economic conditions in other countries don’t matter to us, but that’s not so. Think of the foreign manufacturers building large factories and distribution facilities throughout the U.S., projects that drive concrete production at the most local of levels. Those projects only happen when those companies are enjoying prosperity in their home countries and export markets. In addition, bellwether companies like Caterpillar and the many other construction machinery and transportation equipment manufacturers all benefit from the strong export environment, trade tariffs notwithstanding.Moody’s reported last month that robust economic conditions, elevated confidence levels, and low interest rates will support further expansion, particularly in Asia Pacific and North America; and underpin a stable outlook into 2019. The report, titled “Construction -- Global: Robust economies, higher confidence, and low interest rates keep outlook stable,” sounds a lot like what I’ve been saying for the last two years.Moody’s concludes that continued strong economic growth in a number of major developed and emerging markets, coupled with attractive financing conditions on the back of very low interest rates, will boost average global construction industry revenues by 5% into 2019. An average book-to-bill ratio for the sector forecast at 1.2x also reflects the current healthy industry conditions and suggests sustained revenue growth during 2019 and beyond.Asia Pacific and North America will see the greatest revenue surges at 10% and 6%, respectively. China’s will advance by 8% or more as demand remains strong, mainly in the country's transportation infrastructure segment. In the U.S. and Canada, still-healthy residential activity and a pickup in commercial construction activity will drive volumes. Europe's healthy order books will underpin mid-single-digit revenue growth in the region, bolstered by improved construction-industry confidence and budgetary conditions in several countries, which bode well for residential and public infrastructure spending.Asia Pacific and North America will see the greatest revenue surges at 10% and 6%, respectively. China’s will advance by 8% or more as demand remains strong, mainly in the country's transportation infrastructure segment. In the U.S. and Canada, still-healthy residential activity and a pickup in commercial construction activity will drive volumes. Europe's healthy order books will underpin mid-single-digit revenue growth in the region, bolstered by improved construction-industry confidence and budgetary conditions in several countries, which bode well for residential and public infrastructure spending.But softness does exist in some regions. In the U.K., political and economic uncertainty as well as fragile business confidence due to the ongoing Brexit negotiations will stifle construction output. Latin America's prospects also remain gloomy, with construction companies likely to struggle because of weaker-than-expected growth in some major countries, stagnant investment levels (particularly in Brazil), political uncertainties, shrinking order backlogs, and constrained liquidity.And, finally, higher commodity prices might accelerate investment and support construction activity in the oil-and-gas and mining sectors, mainly benefitting U.S., Australia, Canada, and Latin America-based construction companies.In my last column, I said I remain upbeat about the U.S. construction economy despite a pause in growth in our housing sector. Affordability, labor constraints, and land development are hurdles that must be overcome, and I predict they will be. When we couple improving conditions in the new housing market with further gains in all other construction sectors, I have to tip my hat to Moody’s, and acknowledge they see the future the same way I do.

Joseph C. E. Warnes PE/CE, FACI, FPCI, has released "How to Design and Build Disaster Safe Homes," and "Workable Project Management Procedures for Disaster Reconstruction," books that provide detailed information on how to construct an extreme weather proof home made completely out of concrete. Warnes has a Bachelor of Science in civil/structural engineering from Ohio State University. He is a structural engineer who specializes in disaster-resistant concrete dwellings.Hammurabi's Code of Laws were all-inclusive and a few of them regulated the building contractors of the time. The following codes best represent the rules for construction:228. If a builder has built a house for a man, and finished it, he shall pay him a fee of two shekels of silver, for each SAR built on.232. If he has caused the loss of goods, he shall render back whatever he has destroyed. Moreover, because he did not make sound the house he built, and it fell, at his own cost he shall rebuild the house that fell.233. If a builder has built a house for a man, and has not keyed his work, and the wall has fallen, that builder shall make that wall firm at his own expense.We have known how to build disaster-safe houses for over a half century. Why are we not doing it?Book one demonstrates actual structural calculations for wind velocities of up to 350 miles per hour. A fully concrete-constructed home is what the author believes is the best combination of structural systems to help a building become disaster safe; this includes engineered roofing and walls. Book two describes project management techniques for large-scale reconstruction of houses destroyed by tornadoes, hurricanes, and wildfires.

The floor of the ROTC training room for the Jackson Area Career Center in Jackson, Michigan, was in need of an upgrade. Contractor Anderson Concrete was selected for this project due their relationship with the career center; the contractor has been involved with a building program that brings high school kids to construction jobsites, and their reputable experience with polished concrete.The main challenge in this project was removing two layers of carpet glue that was adhered to the floor. The contractor used a RSP Q8 Nitro Mastic Tool from Runyon to remove the glue. This process would normally be done completed dry, but the contractor resorted to a wet technique because of the glue's thickness. There was also lots of damage to the concrete floor that required substantial patching.Once patching was complete, the floor was polished with 70 grit 100 grit transitional, 400 grit metal, and 400 grit semi-metal and finally up to 800 grit phenolic. Global Polishing Systems products and a Husqvarna PG 820 were utilized to reach the desired polished finish. The contractor polished the floor by stacking silica; no polishing diamonds were used. 

When post-tensioning (PT) tendons are stressed, force in the tendons is reduced due to slippage at the anchors (called seating losses), friction between the tendon and the sheathing (called friction losses), and other long-term losses due to concrete shrinkage, concrete creep, and steel relaxation. Shrinkage is caused by the curing and drying of the concrete after it is placed.Today’s design software can easily calculate the seating and friction losses. However, in the real world, friction calculations provided by system suppliers are seldom considered when detailing the number and location of tendons. Structural engineers should consider these losses during design and not force detailers to make assumptions that can increase the cost and complexity of post-tensioned structures.History: How We Got HereIn the 1970s and early 1980s, post-tensioning suppliers often performed unbonded post-tensioned concrete design as value engineering or as a deferred submittal. They calculated moment redistribution on a slide rule and, later, handheld calculators. Systems and materials were proprietary, with different sheathing, anchorage, and stressing equipment. Some used “stress-relieved” strand and some used “low-lax” strand.All this complicated design made many structural engineers uncomfortable specifying a particular system. Instead, they designed a mild-steel reinforced system with a value engineering option or used a deferred submittal process. But by the mid-1980s, virtually all suppliers had moved to extruded tendon sheathing, making friction and loss coefficient assumptions uniform across the industry. Better design software was developed. Crunching the numbers became less laborious and designs more efficient because engineers could easily analyze alternate profiles and tendon quantities.It became common practice to specify post-tensioning by showing the average force over the length of the tendon. This was perfectly reasonable as long as certain parameters were met – especially considering everyone was assuming a “lump sum” loss that included seating loss, friction, and long-term losses instead of doing the tedious friction calculations.However, the American Concrete Institute (ACI) 318-11 commentary (R18.6.1) states that “lump sum values of prestress losses for pre-tensioned and post-tensioned members that were indicated before the 1983 commentary are considered obsolete.” ACI 318 has recommended against using lump sum losses since the 1985 edition, and the current edition provides references to techniques for calculating friction and long-term losses.I believe Committee 318 expects engineers to take advantage of today’s powerful design software, but most are not. Herein lies the problem. Even though suppliers typically provide friction/loss calculations, most engineers still use the lump-sum method and a final effective force in the tendon of 175 ksi is assumed all along the tendon.Why These Practices are ProblematicThis long-winded introduction brings me to my primary concern: Post-tensioning design software is so sophisticated today that seating loss and friction calculations can easily be considered – and should be. Why they aren’t is a pet peeve of mine for the following reasons.Point 1: Tendon elongations are calculated based on the assumed value of tendon stress of 189 ksi. This is an industrywide non-secret because it’s always on the first sheet of shop drawings.Point 2: Shop drawing tendon quantities are based on the magic number of 26.8 kips per tendon of post-tensioning stress. The PT supplier’s friction calculations are rarely used to calculate tendon quantities. This is another industrywide non-secret.Point 3: Force specifications introduce ambiguities. Where along the tendon is this magic force supposed to be taken? Or is it the average force, the value that’s historically been used?If the specification requires force to be 26.8 at any point along the tendon, additional tendons must be added if just one point falls below that. This may well overstress/overbalance spans closer to the stressing end. ACI’s commentary section states “overestimation of prestress losses can be almost as detrimental as underestimation, since the former can result in excessive camber and horizontal movement.” In one case I know of, the tendon was 2% low in only one span; adding tendons to meet the required force increased the effective force in the span adjacent to the stressing end to 18% above the specified force.This is why friction losses should be considered during design.Adapt Corp.Today’s design software is so sophisticated there’s no excuse for structural engineers to still be using force specifications instead of considering seating and friction losses when determining required number of tendons.Point 4: Another problem with force specifications is the actual number of tendons is not explicit. What is the magic number for force? We used 26.8 kips during my years as head of a detailing department, but the problem is the round-off. Slight changes in the force requirement can increase the number of tendons. In this fiercely competitive industry, that can mean the difference between winning or losing a bid. When you have multiple banded tendons on multiple floors or distributed tendons where the force is highly variable, round-off can result in a significant increase in the quantity of tendons.In this fiercely competitive industry, that can mean the difference between winning or losing a bid. When you have multiple banded tendons on multiple floors or distributed tendons where the force is highly variable, round-off can significantly increase the number of tendons. Expecting the PT estimator to figure all of this out during take-off is unreasonable.Point 5: These calculations should be done by the structural engineer and the required number of tendons specified on structural plans. The actual effective force has a direct effect on the nominal flexural capacity and tensile stresses in the concrete. Due to friction losses, this force varies along the tendon. It also affects balance loading, which in turn reflects in the deflections of the member.In my opinion, the engineer hasn’t completed the design unless these calculations are done. Shop drawing detailers are excellent interpreters of structural drawings, but they’re not engineers; they don’t know anything about loads, member deflections, or member stresses. They only know the codes that directly affect their drawings.Why are they being asked to do part of the structural engineer’s job?Point 6: The other issue with shop drawings is the requirement for a professional engineer (P.E.) stamp. This is also directly related to force specifications.The definition of engineering is met when the forces are used to calculate the number of tendons required. Design software lays out the tendons during modeling. If these quantities are transferred to the design drawings, engineering isn’t required during shop drawing creation and therefore the stamp shouldn’t be required. However, I believe all jurisdictions require shop drawings to be stamped even when tendon quantities are specified.In a perfect world, engineers would specify tendon quantities. Designs would be easier to take off for bidding, easier for the supplier to detail, easier for the engineer to check the shop drawings, and this would eliminate the need for suppliers to have their shop drawings stamped.

The American Society of Concrete Contractors, (ASCC), St. Louis, Missouri., will hold a second Laser Scanning Workshop on Tolerances in conjunction with the 2019 World of Concrete. Dr. Bruce Suprenant, PhD, PE, FACI, CSI: CSSA, CCS, Technical Director of the ASCC, is the workshop coordinator.General and concrete contractors, manufacturers of laser screening equipment, scanning processing companies, and others in the industry will present and discuss 3D laser scanning for concrete tolerances. The morning will feature presentations on separate topics while the afternoon will be devoted to working groups to discuss recommended practices for laser scanning for tolerances. The workshop is by invitation only and is limited to 50 individuals.The objective is to develop content for a draft of the ACI-ASCC 117 Tolerances Committee’s new document on “Guide to 3D Laser Scanning for Concrete Tolerances.” Featured at this year’s workshop will be a discussion of the laser scanning data obtained at an ASCC-sponsored laser scanning repeatability and reproducibility event held in San Francisco in October. The eight participating companies will discuss their best practices for 3D laser scanning for concrete tolerances.The ASCC is a non-profit organization dedicated to enhancing the capabilities of those who build with concrete, and to providing them a unified voice in the construction industry. Members include concrete contracting firms, manufacturers, suppliers and others interested in the concrete industry such as architects, specifiers and engineers. There are approximately 730 member companies in the U.S. and 12 foreign countries.

Cintec North America has undertaken vital restoration work on The Red House, also known as the seat of Parliament for the Republic of Trinidad and Tobago.The project is significant in the history of structural engineering; one of the reinforcement anchors inserted is believed to be the longest in the world, measuring 120 feet in length. It was also the first time that Cintec had used 3D printing for sacrificial parts.In 2007, Cintec’s North American division was asked to advise Genivar, Engineers, (also known as W.S.P) and C.E.P on The Red House’s required repairs. After lengthy discussions with Genivar and having an already triumphant track record in strengthening many of the world’s prestigious landmarks such as the White House and the Egyptian Pyramids, Cintec began working on The Red House in 2017.Cintec’s approved contractor, Celtest of Bangor (located in North Wales), was awarded the contract to install the Cintec Reinforcement System under the guidance of project manager Jason Chinery. Cintec provided additional specialist training and long reinforcements bars to Celest to ensure there would be no long hole drilling issues during the restoration.During trials, it was calculated that the positioning of the drill would be deliberately pointing upwards at 0.50 degrees. This would compensate for the force of gravity pulling down the core barrel, which was over 38m/125 ft in length, and proved extremely effective.Robert Lloyd-Rees, managing director of Cintec North America, said: “Accuracy is critical during a project such as this, misalignment by one degree would mean the drill exiting at the wrong point causing a great deal of damage to the structure.“We spent a great deal of time and used all of our own unique techniques to ensure that the project would be completely successful in restoring such an historic structure to its former glory.”

The SkudoBoard HT INTERLOCK is a heavy-duty, synthetic, rigid board that protects floors under heavy construction traffic. The textured surface of the board never curls or warps. The product can be used wherever you would protect your surfaces with masonite or plywood.The board features innovative interlocking tabs along the edges that secure the boards in place when they are side-by-side, which helps reduce safety hazards on the jobsite. The high compression strength protects from dropping objects and spreads the load evenly under forklifts and material carts, keeping floors safe from damage.Other features include:A lightweight, reusable, and easy to handle designEquipped for use in extreme vertical protectionApproved for both interior and exterior projectsFire-retardantWater and slip-resistantSkudo USABooth S11839More about Skudo USA IncFind products, contact information and articles about Skudo USA Inc

Cement-based overlays aren’t just for floors. You can mimic natural stone, block, brick, leaves, tree bark, animal footprints, seashells, and even fossil renderings quickly and economically with resurfacing products designed for wall applications. They’re lightweight blends formulated to be applied up to 3 inches thick without sagging. Because they go on so thickly, you can create deep rock textures and other designs using stamps or hand-sculpting techniques. Accent coloring with stains or dyes completes the effect, making it possible to reproduce the multitoned, weathered look of natural stone or aged brick.Vertical overlays can be applied to virtually any primed wall surface, including concrete or masonry walls, cement-based backerboard, insulating concrete forms (ICFs), plaster, and drywall. Popular applications include interior accent walls, fireplace fronts, storefronts, entryways, retaining walls, exterior privacy walls, foundation walls, and chimneys.Preparing the Surface for a Tight BondFor a vertical mix to adhere properly, you must follow the manufacturer's recommendations for preparing the wall. First, clean the surface to remove contaminants. Pressure washing is an effective way to clean exterior concrete and masonry walls.If the wall is badly cracked or unstable, reinforce it with expanded-metal lath. I also recommend using metal lath to reinforce exterior walls subject to severe freeze/thaw conditions to ensure a stable support system for the overlay. You can attach the metal lath to the wall with an air-driven nail gun or fasteners.If the wall is extremely smooth, you may need to lightly profile the surface to improve bonding. Methods include sandblasting or application of a gelled acid, an etching product that clings without dripping.After washing the surface and allowing it to reach a saturated surface dry condition, apply a liquid acrylic bond coat as a primer. Without this, the wall could absorb moisture from the overlay and cause the mix to set too quickly. After primer application, some manufacturers recommend applying a thin scratch coat of the mix to improve adherence of subsequent coats.Mixing: It’s All About the RatioThe proper ratio of liquid and dry components is imperative. You want a workable consistency with enough viscosity to hang onto the wall without sagging. If too dry, the mix could crumble off the wall because not enough moisture is present to help it congeal and cling to the surface. If too soupy, the mix will run down the wall. Different manufacturers may have different mix ratio requirements, so check technical data sheets for proper proportions.Mixing procedures are similar to those for horizontal overlays that will be stamped. First, add the appropriate amount of liquid polymer to the mixing bucket or pail. If integral color is to be used, add it to the liquid and mix for about 30 seconds. Slowly dump roughly half the powder into the vessel while mixing with an industrial-type paddle drill running at a minimum 600 rpm. After mixing for 30 seconds, add the rest of the material and mix until thoroughly blended, approximately 3 minutes to 5 minutes.On commercial projects requiring large volumes, follow the same sequence using a mortar mixer.Some manufacturers recommend letting the mixture set for a few minutes to allow the cement particles to fully absorb the available moisture. During this time, called an induction period, the material will stiffen. After the induction period, it's usually necessary to re-drill the mix while adding more liquid polymer until you obtain the right consistency. This produces a more workable mix that won’t set as quickly.Applying the Scratch CoatSome vertical mix manufacturers recommend applying a scratch coat of the material before applying the final texture coat. If this is the case, apply it over the previously primed walls while the primer is still slightly tacky.Application method depends on installation size. One way is to use a hand trowel or a rubber sponge float (commonly used for applying tile grout) to apply the coat in a light, uniform layer no thicker than 1/8 inch. On large projects, you can cover more area faster by using a hopper gun or an industrial spray unit commonly used to apply shotcrete.Don't let too much time pass before applying the texture coat. Typically, if more than 2 hours have gone by, you'll need to apply another light layer of scratch coat.Applying the Texture CoatHand troweling is usually the preferred application method for texture coats. However, some professionals use more creative methods, such as a terry cloth rag—a great way to build up thicker layers when creating faux boulders, for example. On large projects, you can also apply the texture coat with a shotcrete-type spray unit.Don't worry about smoothing it out because you'll be imprinting or sculpting this coat later. It is, however, important to apply the material at uniform thickness to achieve a consistent stamp impression.Pattern profile dictates application thickness. If the stamp is lightly textured, you may get by with ½ inch. A pattern with a deeper profile and distinct grout lines requires a thicker application.If the final thickness you want to achieve exceeds 1 inch, I recommend applying the mix in two builds. For example, to obtain an overall thickness of 2 inches, apply a 1-inch layer and let it set for 15 to 30 minutes. Then go back and apply an additional inch. Don’t let the first coat dry before applying the second one; you want the applications to dry together as one coat to prevent separation.Stamping Tools and TechniquesAlthough some mats used for horizontal stamped concrete are suitable for vertical stamping, you can obtain more realistic results with less effort by using tools designed specifically for vertical applications. They’re usually made of urethane foam or rubber and smaller and more pliable, enabling you to press material into all crevices of the stamp and achieve deeper and more distinct patterns. Stamps for deep patterns are sometimes made of steel and come with texturing skins made of flexible rubber; pre-texture the wall with the skins and then use the steel stamps to form the indents for the grout lines.Like those used on horizontal surfaces, vertical stamp sets are commonly numbered to avoid a repetitious pattern. You also must apply release agent to keep stamps from sticking to the freshly applied mix, but use a liquid rather than a powder.There are many variables in determining proper stamping time. Sometimes you’ll start right after application, some applications require a waiting period. Primary considerations are temperature, wind conditions, coverage area, and thickness. If the mixture starts to sag after you stamp it, you began too soon. If you see tearing at the edge of the stamp pattern, you waited too long.Bottom to Top or Top to Bottom?On some jobs, you'll get better results if you start stamping from the top of the wall working your way down, while others may necessitate stamping from the bottom up. It depends on the levelness of the wall and where you want the pattern cutoff to be less noticeable.On a retaining wall with a cap already in place, you can achieve a full course of brick, block, or stone by starting at the top and working your way down. In this case, the pattern cutoff will be less noticeable at the bottom of the wall. Conversely, if you're stamping a vertical surface that starts from a level slab, starting at the bottom is usually best.Carving Joints By HandThe "carveability" of vertical overlays is a big advantage, especially when you want to achieve stone or masonry patterns with deeper reveals and grout lines than possible with stamps alone.You can use carving tools similar to those used for carving clay. Begin 2 hours to 6 hours after placing the final texture coat. If material adheres to the carving tool, it's too soon and you need to let more time pass. If you get raveling, use a small paint brush dipped in water to smooth out imperfections.Coloring a Vertical OverlayAs with the other cement-based toppings, many coloring options are available to enhance your vertical stamping job. The quickest and easiest way to introduce color is to add a liquid or powdered pigment during mixing. Other options include dyes, paints, acid- and water-based stains, and tints.I prefer water-based stains or latex-based concrete paints because of their ease of application. They come in an unlimited palette and are easily blended to achieve custom hues.Before adding pigments, check with the mix manufacturer to confirm the products you plan to use are compatible with their system. If you plan to stain the wall, allow the freshly applied mix to cure at least one day, longer in some climate conditions. If applied too soon, some stains adversely affect the wall surface. It's also wise to wait a day or so before applying acrylic- or latex-based paints to allow some moisture to evaporate and reduce the chance of moisture becoming trapped within the wall.You can choose from a number of methods to apply accent color, depending on the effect you’re going for. A simple technique I like to achieve a mottled or antiqued appearance is to apply an accent stain by spray and then immediately wipe the stain off the high areas. You can also use traditional faux finishing techniques such as sponging or ragging, stippling with a brush, or hand-painting individual stones.Seal the stamped wall to preserve the work and enhance the color.

Portland cement stucco – a cladding made of sand, cement, and lime – has been used to beautify and insulate buildings around the world for centuries. Applied in two or more coats to surfaces including masonry and concrete walls, the material is durable but breathes, allowing water vapor to escape. Foam shapes such as cornices, quoins, or window surrounds can be added and finished with a cement or acrylic coat in a wide variety of colors and textures. It is, according to the Portland Cement Association, a proven system that works in all climates.Over the last century, enhancements such as crack-suppression membranes, foam insulation, and rainscreen as well as new products, such as exterior insulation finishing systems (EIFS) and polymer-based (PB) systems, were introduced. What was once a fairly straightforward product category is now a bewildering array of assemblies, systems, terminologies, standards, and applications methods. What can your clients reasonably expect?The Stucco Manufacturers Association cuts through the clutter during World of Concrete Jan. 22 through 25, 2019, with STUCCO LIVE! Nine popular assemblies, including continuous insulation and rainscreen systems, will be used to demonstrate what’s available and how to best install and maintain the material. There will be particular emphasis on eliminating water intrusion from the slab and foundation and installing moisture prevention barrier systems.Attendees will learn about the two ASTM standards governing construction:C1063, Standard Specification for Installation of Lathing and Furring to Receive Interior and Exterior Portland Cement-Based PlasterC926, Standard Specification for Application of Portland Cement-Based Plaster.In addition to the basics, attendees who stop by Booth C3055 in the Las Vegas Convention Center’s Central Hall will hear about industry trends from their peers and instructors.Instead of a generic blend of products from unknown sources, plasterers are increasingly using engineered mixes. Designed to meet established performance criteria and blended at a factory under strict quality controls, the mixes increase productivity and limit liability. Stucco accounts for 25% of cladding in the U.S., and plasterers who supplement hand tool application with machines are making stucco more affordable in regions where it hasn’t been a traditional cladding.

Photovoltaic cladding is a concrete prototype by materials company LafargeHolcim and electronics maufacturer Heliatek. The concrete features a top layer of HeliaFilm; a flexible solar trip that is only one millimeter thick. The prototype has the potential to largely increase the generation of solar energy due to the larger surface area of a concrete facade compared to traditional roof-based solar panels.Weighing less than five per cent of a traditional solar panel, HeliaFilm is made to be integrated into construction materials by building element manufacturers. Beyond LafargeHolcim's concrete cladding, it could be used with steel or glass.

At an industry conference earlier this year, I sat in the conference center hallway to review afternoon breakout sessions that were starting in a few minutes. I saw one titled something like “Attracting and Retaining Millennials into the Workforce” and decided that was a topic I needed to learn more about. When I walked in, I was stunned: Every seat was filled and people were standing three-deep on three sides of the room. I elbowed my way into a corner, only to hear what many of us already know: Attracting and retaining millennials is as big a challenge as our industry has faced as this generation’s traits and preferences continue to puzzle human resource departments nationwide.Now the popular business press reports an even bigger issue related to millennials: Men are missing. Ten years after the Great Recession, 25-to-34-year-old males are lagging in the workforce more than any other demographic. About 500,000 more would be punching the clock today had their employment rate returned to pre-downturn levels. That’s unfortunate, because they’re missing out on a hot labor market and crucial formative years, ones traditionally filled with the promotions and raises that build a strong foundation for a career.Men, who many say have long been America’s economically privileged gender, have been dogged in recent decades by high incarceration and disability rates. They hemorrhaged high-paying jobs after technology and globalization hit manufacturing and mining. But young men have fared particularly badly. About 14% of 25-to-34-year-old males with just a high school degree weren’t in the labor force in 2016, up from 6.4% in 1996. Many exited high school into a world short on middle-skill job opportunities and were then broadsided by the worst downturn since the Great Depression. Employment plummeted across the board from 2007 through 2009, but young men fell far behind their slightly older counterparts and haven’t caught up. Millennial males remain less likely to hold a job than previous generations, even as women their age work at higher rates.Their absence has economic and social consequences. Loss of talent slows innovation. Young people who get a rocky start in the job market face a lasting compensation penalty. Economists partly blame the decline in employed marriageable men for the recent slide in nuptials and increase in out-of-wedlock births. Those trends foster economic insecurity among families, which could worsen outcomes for the next generation.It’s difficult to know if young men want to remain on the sidelines or are kept there by a dearth of attractive options. They could be choosing to stay home or enroll in school because high-paying, non-degree jobs in industries like manufacturing are fewer and farther between. But it isn’t clear why lost opportunity would hit this demographic hardest.Other social changes could be exacerbating the trend. Better video games might make leisure time more attractive, some economists hypothesize; and opioid use might make many less employable. Young adults increasingly live with their parents, and cohabitation is also more prevalent in this demographic.So the question looms: Is the group’s employment decline permanent? Our challenge is to recalibrate the industry’s approach to recruiting and retaining millennial males and find a way to permanently integrate them into the workforce. Given our labor challenges, we can ill afford to overlook this critical demographic.

Command Alkon, provider of integrated supply chain technology solutions for the heavy buildings materials industry, will now offer a Graduate Development Program at their headquarters in Birmingham, Alabama. The program will provide the opportunity for graduates of MTSU to gain management experience in order to create a workforce that is qualified to fill in the gaps caused by labor shortages.The two-year program will allow students to rotate between different departments (sales, human resources, batch, finance, product management, and customer success) for the first 18 months. The exposure will help students understand the contributions that each team makes to the company and the industry as a whole. The student will then choose an area of the company where they feel they can thrive for the last six months of the program.Industry trends show that 25-to-34-year-old men are significantly absent from the workforce, dealing a substantial blow to an already suffering trade. Thousands of construction jobs open up every month, but recruitment has been burdened by few colleges and universities offering construction skills or counsel for students to consider high-paying construction careers.The School of Concrete and Construction Management at MTSU offers a Concrete Industry Management (CIM) Program designed to combat the anticipated shortage of managers needed to support the expected growth of the concrete industry. Command Alkon has fostered a close relationship with the CIM Program over the years and has developed a program designed to arm students with the experience that they need to be successful.“A lot of the time, we look to hire individuals with experience in the industry – but, that might be a little difficult to find in a student who just graduated.” says Michael Wolfe, People Business Manager at Command Alkon. “The whole point of this program is to provide an opportunity for these students to gain the experience that they need. Each department in the company has made the commitment that we are all going to contribute to the student’s success in some way.”

Every business owner says people are the key to success. Merlo Construction Co. in Milford, Michigan, makes sure employees are successful as individuals and as team members.“A wise man once told me, ‘People come to Merlo Construction and leave Merlo Construction for the same reason: opportunity,’” says Ray Merlo, who launched the business with his brother Perry in 1991. “Good employees want to know there’s room for advancement, so we encourage managers to continually provide opportunities for each employee to grow professionally.”To help managers do that, the company holds quarterly off-site meetings that include a ‘state of the union’ address and team-building exercises. Winters bring the ‘Off Season Hustle,’ where superintendents send employees to programs ranging from riding trowel school to Occupational Safety and Health Administration (OSHA) training to GPS training.” All managers are OSHA 10- or OSHA 30-certified and have first aid/CPR training.Finding skilled labor is increasingly difficult, but Merlo cautions against holding on too long to managers who don’t support the organizational culture. “It’s more important they share your philosophy on customer relations,” he says.The Merlo brothers’ father, Reno, was also a concrete contractor. Ray and Perry worked for him during summer vacations, so they grew up with a shovel and trowel in hand. After high school, Ray went to Lawrence Technological University in Southfield, Michigan. Perry worked full-time with their father. After earning a bachelor’s degree in business management, Ray worked in another industry for six years before going into business with Perry when their father retired.About 60% of Merlo’s work is concrete construction and 40% is demolition, earthwork, grading, and underground utilities, a capabilities mix that enables the company to provide turnkey solutions. “General contractors and owners can have one contractor handle much of their project,” Merlo says. “Dealing with one contractor for different project phases aids the customer in scheduling, and working with crews from the same company gives us a cost advantage.”It also means Merlo has a capital-intensive equipment fleet. To ensure precision and accuracy, Merlo’s invested in laser-guided pavers and screeds. Projects begin with a digital, onscreen takeoff. That data is entered into software to prepare a detailed estimate. When the project’s awarded, Merlo creates and uploads GPS files to the equipment.In 2013, Merlo earned an Ohio Concrete Association Project of the Year award for its work on a new FedEx distribution center in Ohio. After persuading the owner to switch from asphalt to 6.5-inch concrete that would last 20 years, crews placed and finished 1 million square feet. Judges said Merlo won the job despite intense competition “due to their ability to combine technical knowledge in concrete as well as site excavation to value engineer this project into viability.”The client must agree, because Merlo is preparing to break ground on another FedEx facility. Last year, Merlo successfully placed a slab on grade for a Guardian Glass plant that opened joint spacing to 120 feet by 120 feet with the addition of steel fibers.With the uptick in southeast Michigan’s economy, Merlo has an eye on growth. That goal is being facilitated by Director of Operations Brian Misaras, who came on board two years ago. The training and opportunity given to employees to lead others has been a successful plan of expansion and growth, from 55 employees in 2014 to 130 today

The Mason Contractors Association of America (MCAA) has contracted with XYZ University to research the intergenerational issues impacting todays jobsites. In particular, they are exploring how employees can more effectively communicate across generational boundaries to be more productive and retain workforce.XYZ University has written an in-depth white paper on the topic and have developed a two-day program debuting at World of Concrete that will train employees on how to adapt skills to mitigate generational conflict. This two-day program is fantastic for anyone in a supervisory role and/or anyone who deals with multiple generations in their daily work.Day 1 - Jan. 20, 2019:8:00 a.m. – 4:00 p.m. – MCAA Workforce Initiative – Part 1, including: seminars, workshops, and interactive learning activities4:00 p.m. – 5:00 p.m. – Happy Hour Networking EventDay 2 - Jan 21, 2019:8:00 a.m. – 3:00 p.m – MCAA Workforce Initiative – Part 2, including: seminars, workshops, and interactive learning activities3:00 p.m. – 4:00 p.m. – Talent Generation Book Signing and Networking Event (included with the price of seminar)Location: Las Vegas Convention Center, N212The experienced team at XYZ University will share tools and insights they’ve developed over 16+ years of generational research and expertise, including improving internal workforce culture (and ultimately productivity) and best practices for effective workforce development.The class is available to non-member firms for $1100, however, the MCAA is offering a special discount to Concrete and Masonry Related Association (CAMRA) members through Dec. 21. CAMRA-affiliated organizations can use the discount code CAMRA to bring the cost down to $950.The price includes two light continental style breakfasts, two lunches, a happy hour reception and the book Talent Generation: How Visionary Organizations Are Redefining Work and Achieving Greater Success.

Last week I got a new knee—well, more of a rebuilt knee. The surgeon (repair technician) removed the old worn out parts and installed nice shiny new ones made of titanium, zirconium, and high-density plastic guaranteed for high durability. It’s a remarkable advance in technology when you consider that 50 years ago I would have had to just suffer with a worn out knee for the rest of my life. I’d like to file a warranty claim on that joint but am not sure where to send it and I guess I got my money's worth after 65 years of abuse.Although advances like this in the concrete industry may not happen at the same pace as in medicine and electronics, they do happen and the best place to find out what’s new is at the World of Concrete. You can learn about innovations at other meetings, like ACI conventions, but nowhere is so much concrete knowledge jammed into one place as at the World of Concrete.Some of the most important advances I see coming to our industry over the next few years, though, are bigger than the impressive new materials, equipment, and technology you'll see at WOC but rather focus on with how we do business. It starts with adopting a collaborative approach in construction, which is effective in almost all circumstances and that starts with design-build (or integrated project delivery) and evolves into lean construction and post-project analysis. Creating a feedback loop to evaluate a project in real time can prevent the same mistakes from happening over and over.Resilient construction is also becoming a focus. Resilience is different than durability or sustainability; resilience is a structure’s ability to withstand the increasingly common natural and man-made disasters it is subjected to. Green construction (sustainability) has a more immediate benefit and has turned into the way we all work but designing and constructing for the long haul—for 100-year service life—and to withstand hurricanes and fires and floods that people and structures are facing, that’s a new mindset.If my new knee can last 40 years, I won’t complain but if the structures we’re building and repairing today only last 40 years, that’s unacceptable.

In 1992, the U.S. Environmental Protection Agency launched a program designed to lower greenhouse gas emissions by encouraging development and use of energy-efficient products. Most people think the ENERGY STAR label applies only to products, but structures are also eligible. An apartment or condo building that’s 15% more efficient than code requirements, for example, qualifies for the rating.Last year, a 13-story residential building in downtown Detroit earned Michigan’s first ENERGY STAR rating. Only 10% of the project – the foundation and a structural podium that runs from the first to second floors – is cast-in-place. Kraemer Design Group specified precast concrete panels for the rest of the building, interior as well as exterior, because they’d help the project meet ENERGY STAR requirements.There were other compelling reasons for precast as well.The building, called 28 Grand for its location on Grand River Avenue in downtown Detroit, isn’t a typical apartment building. The 13-story building contains 218 micro-units, so-called because they’re an average of 250 square feet. Precast’s sound-dampening properties and extremely high fire-safety rating are a bonus for multifamily buildings. Painted concrete walls and ceilings eliminated the need for additional investment in drywall or other interior finishes.The building’s footprint consumes an entire 8,957-square-foot corner lot, so equipment and materials staging space was virtually nonexistent. The project was on a tight deadline as well. Using precast elements overcame both challenges. Panels were fabricated offsite and shipped per an aggressive schedule that was developed and closely coordinated with the factory. Upon arrival at the jobsite, they were off-loaded directly from the truck and hoisted into place, minimizing the potential for damage.Precast also satisfied various aesthetic requirements.To fit in with the neighborhood, the city’s Historic District Commission required punched windows and a masonry façade. The goal of replicating the look of limestone, a commonly used exterior cladding material on many historic Detroit buildings, was achieved via a custom pigment mix and acid finish. Black bricks were cast directly into the panels for the lower two floors to satisfy the design aesthetic while maintaining the quick construction cadence.The exterior design also reduces the opportunity for water to penetrate the wall assembly, preventing future water damage. The exterior skin is self-supporting, requiring a low number of tiebacks to the main structure; and a gap between the exterior wall and floor slab edge allows for the running of continuous insulation. Thermomass insulated precast sandwich panels were used at strategic locations to minimize thermal bridging. Introduced 30 years ago by Australian company Composite Global Solutions (CGS), the panels incorporate the structure, insulation, vapor barrier, and exterior façade for a seamless installation process. They were shipped in and assembled just like the typical precast panels, only they came from the factory with a layer of insolation between two layers of precast.With fully furnished studio apartments, extensive amenities, and easy access to downtown Detroit destinations, 28 Grand is the next big thing in city living.

BASF now provides third party-verified Manufacturer Inventory Reports for all its admixture and fiber products to meet the requirements of the LEED v4 Building Product Disclosure and Optimization – Material Ingredients, Option 1 credit.In 2017, BASF was the first admixture company to provide third-party LEED v4-compliant Manufacturer Inventory Reports through GreenCircle LLC. The environmental consultant company audited and verified that BASF’s internal Product Compliance Management System assesses the hazards of all the ingredients that make up the product, including impurities. This verification provides BASF with the capabilities for certifying its entire portfolio of Master Builders Solutions products.“With the GreenCircle Certification, we ensure an independent authentication of our company’s product sustainability claims and help architects and design engineers make educated product selection decisions during the research and design phase of a project,” said David R. Green, Manager Applied Sustainability for BASF Construction Chemicals. “BASF is committed to providing product material transparency information to support the construction industry’s efforts to deliver healthy and sustainable solutions to the built environment.”BASF offers a wide range of sustainability tools and service solutions to support the construction industry. These include externally verified, ISO compliant declarations for concrete products (Environmental Product Declarations, EPD); a comparative life cycle assessment methodology that balances the cost and environmental impacts of alternative products, processes and technologies (Eco-Efficiency Analysis, EEA); and the Green Sense concrete advanced mixture optimization service to produce high quality, environmentally-preferable concrete. These value-added service solutions are available to all BASF customers.“Environmentally-preferred products are truly changing how construction material selection decisions are being made”, said Green. “Demand for transparent information on products and solutions in all business sectors will continue to grow.”To learn more about BASF sustainable products, service solutions or to locate a local BASF representative, visit www.master-builders-solutions.basf.us. To learn more about GreenCircle visit www.greencirclecertified.com.About the Construction Chemicals divisionBASF’s Construction Chemicals division offers advanced chemical solutions under the global umbrella brand Master Builders Solutions for the construction, maintenance, repair and renovation of structures. The brand is built on more than 100 years of experience in the construction industry. Our comprehensive portfolio encompasses concrete admixtures, cement additives, chemical solutions for underground construction, waterproofing systems, sealants, concrete repair & protection systems, performance grouts, performance flooring systems, tile-fixing systems, expansion joints & control systems and wood protection solutions.The Construction Chemicals division’s approximately 6,500 employees form a global community of building experts. To solve our customers’ specific construction challenges from conception through to completion of a project, we draw on our specialist know-how, regional expertise and the experience gained in countless constructions projects worldwide. We leverage global BASF technologies and our in-depth knowledge of local building needs to develop innovations that help make our customers more successful and drive sustainable construction.The division operates production sites and sales offices in more than 60 countries and achieved sales of about €2.4 billion in 2017.About BASFBASF Corporation, headquartered in Florham Park, New Jersey, is the North American affiliate of BASF SE, Ludwigshafen, Germany. BASF has more than 18,200 employees in North America and had sales of $17.9 billion in 2017. For more information about BASF’s North American operations, visit www.basf.com.At BASF, we create chemistry for a sustainable future. We combine economic success with environmental protection and social responsibility. The more than 115,000 employees in the BASF Group work on contributing to the success of our customers in nearly all sectors and almost every country in the world. Our portfolio is organized into five segments: Chemicals, Performance Products, Functional Materials & Solutions, Agricultural Solutions and Oil & Gas. BASF generated sales of €64.5 billion in 2017. BASF shares are traded on the stock exchanges in Frankfurt (BAS), London (BFA) and Zurich (BAS). Further information at www.basf.com.

Concrete would be nothin’ without rebar. Engineers have used steel for centuries to help concrete resist tensile as well as compressive forces. Today, reinforcing steel employs 15,000 people at 450 fabricating locations in more than 45 states; moving and placing reinforcing steel employs 75,000 people. Eight million tons are manufactured every year.Formed in 1924 to develop standards governing design and construction, the Concrete Reinforcing Steel Institute (CRSI) has recognized particularly noteworthy projects for almost four decades. This year, 19 projects exemplify excellence in satisfying owner objectives, problem-solving, maximizing value, using rebar right, and – of course, aesthetics. Twelve entries received an HONORS Award; seven received a Merit Certificate.MERIT CERTIFICATEBridgeCapital Cascades Crossing Pedestrian Bridge (Tallahassee, Fla.). Submitted by Figg Bridge Engineers.EntertainmentJohn F. Kennedy Center Reach Expansion (Washington, D.C.). Submitted by R&R Reinforcing.Multifamily Residential/HotelHalcyon Hotel (Denver). Submitted by Cary Kopczynski & Co.Mr. Robinson (San Diego). Submitted by DCI Engineers.Office512 W. 22nd St. (New York). Submitted by DeSimone Consulting Engineers.Dallas Park District (Texas). Submitted by Brockette/Davis/Drake.McDonald’s Headquarters (Chicago). Submitted by James McHugh Construction.

A dedication ceremony for an extensive new hardscape at the Warner Unified School District in northeast San Diego County, California, was held on Nov. 14, 2018. The hardscape was donated by two specialty councils of the American Society of Concrete Contractors (ASCC), the Decorative Concrete Council (DCC) and the Manufacturers’ Advisory Council (MAC). Members of the DCC and MAC, along with other ASCC members, donated all labor and materials for the project.First, the old concrete was demolished. Sedimentary seat walls, a stage with valley mosaic, concrete paths, and other enhanced paving were complete. Additional features included a wall designed to simulate Hot Springs Mountain, boulders, tribal mosaics, a stencil of the school mascot and resurfaced athletic courts that were installed by volunteers. Nine donated trees were planted around the stage and two precast concrete corn hole games were part of the project. The sprinkler system will be renovated over Christmas break. In total the project encompasses $250,000 of landscape rehab.Byron and Chris Klemaske, both with T.B. Penick & Sons, San Diego, led both the fund raising/donation portion of the project, as well as the construction management. Chris Klemaske is a past president of the DCC and Byron serves on the board. “One of the most gratifying experiences was getting the students involved in the construction process,” says Byron. “It helped the professional crew and gave the kids ownership of the project.”“Nothing really centralized the changes taking place at Warner Schools like the ASCC project,” says superintendent/principal David MacLeod. “When I was told that a local couple was interested in doing a concrete project, I was all in. This project has created a center focus on our high school campus. It repaired or removed some old eye sores and left a piece of art. This happened at the perfect time, our 80th anniversary of the school and at a time when it really solidified that Warner was going through changes both physically and culturally.”The Warner United School District was built in 1938 and has a long history. Due to its rural setting it is the hub of the community, according to MacLeod.The ASCC is a non-profit organization dedicated to enhancing the capabilities of those who build with concrete, and to providing them a unified voice in the construction industry. Members include concrete contracting firms, manufacturers, suppliers and others interested in the concrete industry such as architects, specifiers and engineers. There are approximately 730 member companies in the United States and 12 foreign countries.

Wacker Neuson has announced a unique apprenticeship program to help fill the growing need for qualified machine technicians in the construction industry. Wacker Neuson has teamed up with the State of Wisconsin Department of Workforce Development (DWD) to create an apprenticeship program that allows students to “earn as they learn.”“The program is intended to act as a funnel for qualified technicians into our dealer network,” explains Jake Gaylord, technical training manager for Wacker Neuson and author of the program. “As a manufacturer, we heard from our dealer channel partners that they have trouble finding qualified skilled technicians to work on their equipment. We designed the apprenticeship program to help fill this gap by allowing technical apprentices to receive paid related instruction and on-the-job training at the same time.”The paid related instruction uses a hybrid approach of both online and instructor led training to complement the on-the-job tasks and experience. During the two and a half year apprenticeship program, students are employed by a dealer, and are required to come to Wacker Neuson’s facility one week a month for paid related instruction. Instruction is provided by Wacker Neuson University which also relies on the local technical college system to provide “life skill” training, such as employment success and communication.“This approach provides a very specialized curriculum with direct application to the on-the-job activities,” according to Gaylord. “There is minimal cost to the students and they earn while they learn without incurring debt. At the end of the program, the apprentices will have earned journeymen status and are fully qualified technicians in machine diagnostics, maintenance and repair of all Wacker Neuson construction equipment and similar equipment.”Wacker Neuson will be recruiting for the program and will focus on high school graduates, veterans and women, as well as work with the existing dealer network to seek candidates.“This is a unique program. We created a new job description, ‘Construction Equipment Technician’, that combines the skills of a diesel engine technician and mobile equipment technician into one job,” says Gaylord. “We are addressing the needs of our dealers and training world class technicians while they are earning wages. It’s a true win-win program for everyone.”

You’ve probably seen the video of a 3D printer that creates a beehive-shaped house. Will 3D printers replace your foundation crew? How long until riding trowels are automated? Until Tesla introduces self-driving mixers? Maybe in our lifetimes, maybe never…who knows? Should we worry about it or should something else be bothering us?I remember when jobsite plans weren’t drawn up on computers, when the term CAD-CAM was practically unheard of. It seems like just yesterday we had to run to a payphone to release concrete. When bag-phones came out…man, oh, man. Does anyone else remember the first riding trowels had three decks instead of two? How about when laser levels came out, way before laser screeds were introduced?Artificial intelligence, robotics, and automation have revolutionized manufacturing, in many cases displacing or replacing human labor. We might say, “That will never fly in concrete;” but Henry Ford probably had no idea what would take place in Detroit, either. Regardless of what the future holds, technological advances don’t keep me up at night.Our industry’s seen a lot of changes, but the essentials remain the same. Regardless of what new tools and processes come down the line, our industry will always need skilled tradespeople – finishers, masons, equipment operators, mechanics, carpenters – who are passionate about their work. And that, my friends, does worry me.Too few people are entering the trades and too few of my peers seem to care. I follow successful concrete contractors on social media, and some are making a valiant effort to bring in fresh blood. But job fairs, apprenticeships, internships, and want ads aren’t enough to fill the coming void. I don’t have all the answers to our problem, but I think I know what one of our blind spots is.There’s an old saying that goes something like, “If you don’t have any followers, are you really a leader?” We need to flip that phrase. If we don’t develop leaders, how can we expect our organizations to generate more followers? As a teenager, I was nearly mesmerized by some very charismatic leaders in our industry. Many have retired or, sadly, passed away. Why haven't we replaced them?Ninety-nine of 100 people in the field laugh at the idea of leadership development, but 100 of 100 fondly remember the mentoring they received from the folks who taught them and shaped them. One of the best parts of working in concrete is the amazing sense of accomplishment we experience when a project wraps up. We aren’t finished yet, though. We aren’t done with our work until we raise up the next generation of tradespeople who can replace us. There is nothing more fulfilling than developing those who will follow in our footsteps. I hope you’re not missing out on the best part of our job.

Two seaports, an international airport, and rail and trucking facilities are luring online retailers and regional distributors into Atlanta in record-breaking numbers. As a result, the nation’s ninth-largest metropolitan area has the fourth-largest amount of industrial space. Almost 13 million square feet were filled in the first half of 2017 while 7.7 million square feet of speculative space were being built.Danko Concrete Construction is perfectly positioned to capitalize on this growth, and not just because it’s located in Altanta. The 20-year-old company provides any combination of foundations, slab-on­-grade, elevated deck, paving, and/or pit-and-trench work a client needs via turnkey solutions from estimating and budgeting to post-completion tenant fit-up. However, its specialty is large-scale buildings. Since 1998, the award-winning Tilt-Up Concrete Association (TCA) member has installed more than 20 million square feet of warehouse and distribution facilities throughout the Southeast.One such project was Project Murphy in Lambert Farms Logistics Park in the City of McDonough, an Atlanta suburb. The 1.6-million-square-foot building is Georgia’s largest warehouse, requiring 1 million square feet of concrete pavement and 270,000 square feet of concrete panels.Collaboration between general contractor and subcontractor on any project is paramount, but particularly so on such a behemoth. Two to three TCA- or American Concrete Institute (ACI)-certified superintendents were onsite at all times to reinforce communication. All superintendents are trained on the DANKO Way, best practices for forming, pouring, and setting panels.“This was a fantastic project,” says Bill Clifton, who managed projects for several general contractors for 12 years before launching his company. He has a bachelor’s degree in building construction from the Georgia Institute of Technology and a Master of Business Administration from Georgia State University. “It exceeded everyone’s expectations regarding schedule, production, and overall efficiency.”“How a firm works with others to address problems is the true indicator of character,” says Tim Evans of Evans General Contractors, which has worked with Clifton almost since Danko’s founding on projects including design-build delivery. “Regardless of the challenge, their people step up to meet client expectations regarding quality, budget, and schedule.”A CEO can’t be everywhere at once, so Clifton empowers employees. Many have been with him for more than 15 years. Danko looks for talent everywhere and supplements knowledge gaps with manufacturer-sponsored training and certification on things like mix design, curing, joint treatment, and hardener application. Danko’s a Ductilcrete Alliance member and has ACI-certified flatwork finishers working in positions ranging from technician to supervisor.“We go out of our way to exceed the needs of our employees,” says Clifton, “and in turn they provide outstanding craftsmanship and quality that can’t be beat.”

The Concrete Sawing & Drilling Association (CSDA) is proud to announce that Captain Kent Ewing, a retired Naval officer, will be keynote speaker during the association’s 47th Annual Convention & Tech Fair. The convention will be held at the historic Vinoy Renaissance Resort & Golf Club in St. Petersburg, Fla.Captain Ewing was Commanding Officer of the USS America (CV-66) during Desert Storm. In his naval career, he also commanded Carrier Air Wing Seventeen and Attack Squadron Sixty Six. He has flown over 18,500 hours in over 100 different military aircraft and made over 1,150 carrier landings. He holds a Bachelor of Science degree in Economics from the University of California at Los Angeles and a Master of Science in Systems Management from the University of Southern California. A Dayton, Ohio native, Ewing is a 1974 graduate of the U.S. Navy Test Pilot School, Patuxent River, Class of 1965.“CSDA is proud to have Captain Ewing join us and he has a special connection to MacDill Air Force Base which is only 8 miles from the Vinoy. This base is the headquarters for Special Operations Command (SOCOM) and Central Command (CENTCOM) which has responsibility for the conflicts in Afghanistan and Iraq, including Dessert Storm in 1991. CSDA is proud to honor and recognize Captain Ewing and all the men and women who serve our country” added CSDA Executive Director, Patrick O’Brien.Captain Ewing will share stories of his unique experiences leading over 4,000 sailors in wartime and what lessons on leadership he learned from the navy. By successfully commanding men and women from those in their teens to experienced veterans, he will provide CSDA Convention attendees a new perspective on ways to lead and motivate their operators and employees, as well as provide some entertaining stories about life on an aircraft carrier!The CSDA Annual Convention & Tech Fair is attended by owners, managers and operators from concrete cutting, polishing, and imaging companies as well as representatives from manufacturers and distributors who support the industry with products and services. Anyone who is a part of this industry should join CSDA for this action-packed event. 

Over the past several years, Mike Murray’s Concrete Cares has been raising money to help families in the concrete industry that are affected by cancer. You may recall that we recognized Mike as one of our Most Influential People a couple of years ago.Recently Mike sent me this letter from Paige West: “My daughter McKenzie was diagnosed with leukemia at 13. After the shock of the diagnosis we started thinking about what it would take to care for her and how to balance it all financially and emotionally. When we found out that her chemotherapy would be every week for the next two years and seven months, we couldn’t fathom how we would be able to keep up with our financial responsibilities since we are a two income, paycheck to paycheck family. We knew this diagnosis would keep me from working full time. McKenzie was in the hospital for a lengthy stay at the beginning of her treatment. Thanks to the generous donations made through Concrete Cares we were able to keep our home and pay our monthly bills while I focused solely on caring for my daughter. I will never be able to fully express what a relief this was to my family and how thankful we are to Concrete Cares.”

Welcome to Concrete Boom Pumping 101 – class is now in session.This equipment overview – and accompanying discussion of the human and site factors that bear heavily on performance and safety – is designed to help contractors increase their familiarity with what’s happening on their jobsites when a concrete pump with boom is at work.You’ll leave with a basic understanding of concrete boom pump features and how they benefit different applications, whether you’re a “renter” of pumping services or a prospective pump buyer whose annual subcontracting costs are moving you to consider ownership. It’s unquestionably a significant investment that generally ranges from the low hundred-thousands to north of $1 million, so taking time to sort your priorities and preparing questions to ask manufacturers and peers is well worth your time.Besides its definition in equipment vernacular as an extending “pole,” if you will, the word “boom” used as big noise and big prosperity also applies. Using a boom to pump concrete replaces labor-intensive crane-and-bucket methodology and has brought a loud and lucrative productivity into the business of building everything from bridge decks, home foundations, high rises, and commercial buildings to parking lots and garages, swimming pools, and more.For the sake of clarity, before we open the proverbial textbook, a word about “renting” in the context of concrete pumping: Unlike the rental of earthmoving construction equipment, the rental of boom pumps is synonymous with subcontracting. Renting a boom pump is almost always joined at the hip with renting the operator; rarely would (or should) a boom pump be rented and operated by a contractor’s personnel. The complexity of the equipment dictates highly trained, highly skilled operators, and no one without American Concrete Pumping Association (ACPA) should ever be at the controls.Your Jobsite – Act 1, Scene 1To set the stage of a typical urban jobsite, meet Eric Lindquist, president of 80-year-old family concrete pumping business Adjustable Forms in the Chicago suburb of Lombard. The company works almost exclusively in downtown Chicago on high-rises, and four to six simultaneous jobs is their sweet spot. Logistics, Lindquist says, is one of their top challenges.Picture the scene: Tight, highly confined building sites with severely restricted access makes staging ready-mix trucks a choreographic feat. Couple that with constant vehicle, pedestrian and bicycle traffic, and you’ve got a jobsite peppered with pressure.Now add several tons of pumping boom equipment to the mix and you’ve got yourself a pretty intense drama.And the nature of concrete itself really pours on the pressure.“Concrete is one of heaviest building materials that exists and it’s very caustic,” says Tom O’Malley, senior vice president of sales and marketing for Schwing America Inc. in St. Paul, Minn. “It’s a time bomb, too, because it’s an extremely perishable product – and we literally shove this material through a 5-inch pipe to get it where it needs to be. It’s high pressure, high energy consumption, and a high risk.”Not only that, but jobsite attitudes toward pumping have in some cases taken a turn for the worse, adding more stress to an already difficult plot.“People sometimes look at it as a ‘hurry-up’ tool,” says Eric Wright, concrete technology product manager for Liebherr USA Co. in Newport News, Va. “I’ve seen situations where the boom truck pulls up and they say, ‘Just go set up over there in the mud and be ready in 45 minutes’ while the crane gets a day to set up. The pump is just as sophisticated and needs just as much stability on the ground. You have lots of people working under the boom just like a crane.”Pumping With Reach – Your OptionsWith all that tense and buzzing jobsite activity as a backdrop, let’s move in closer for some machinery details.When the pour site is high above ground, high with low overhead areas, crowded, environmentally sensitive, or just plain hard to get close to, you’ve got a couple of choices as you consider pumping concrete with boom equipment.Truck-mounted boom pumps. The vast majority of concrete pumped in the U.S. is pumped by this style. You’ll get an approximate range of reach from under 20 meters to as high as 70 meters. Because boom pumps originated in Europe, they’re specified in metric terms; 1 meter equals a little more than 3 feet, so you achieve more than 200 feet of reach with a 65-meter boom, for example.The truck and boom together are a formidable weight, to the tune of 30 tons in some cases, so expect to pay sizeable DOT permitting fees. Frost laws in the coldest states limit pounds per axel to as low as five tons, so owners sometimes have to get creative with adding extra axels to comply with these restrictions.Placing boom with a stationary pump. Challenged by a multistory high-rise that’s growing taller by the week? Here’s the super hero equipment that literally “flies” to the rescue.Used almost exclusively in this type of application, a placing boom is whisked high in the air to a tower crane pedestal where it can then reach in to pour each subsequent floor level. In this scenario, a large stationary pump on the ground heaves hundreds of truckloads of concrete per day through lines of steel and rubber hose that are snaked up through the elevator shaft, for example. The longest placing booms are in the 39- to 43-meter range.A placing boom often remains on the jobsite for the duration of the project, which is how Lindquist’s Adjustable Forms company operates. He owns six units, making his fleet of placing booms one of the biggest in Chicago.Side note: Made by Construction Forms Inc. (Con Forms) in Port Washington, Wis., an alternative product called Spider Placers acts as “an extension cord” to give the pumping job 16 meters to 18 meters (up to 60 feet) of reach; the 18-3 model is a tracked, drivable unit. These, too, must be flown into position with a crane.Truck-mounted with detachable boom. Combining the advantages of truck-mounted portability and placing booms’ adaptability to rising elevations, some manufacturers offer a detachable boom off the truck – it functions like a placing boom but uses the truck’s pump kit. Detachables account for only about 10% of boom pumping usage in the U.S. That may be due in part to the high cost associated with a specialized feature that’s used only on the largest structures.It may be a no-brainer, but nonetheless: The bigger the boom, the greater the cost.But bigger is not always better, despite predominant thinking in our culture, says Wayne Allen, national sales manager at CPE America in Metter, Ga. A smaller boom pump can be a more versatile solution for a wider range of jobs.“Price goes up for two reasons: the engineering and technology to make that boom length possible, and the cost of the truck that carries the pump,” he says.Used Market ThoughtsIf you’re considering used equipment, know that higher end, high-quality units hold their value very well. Some companies, including Adjustable Forms in Chicago, turn their fleet while it’s still young and well before some would deem necessary. Therefore, good used machines are out there.“Of course, the older the machine, the more careful you should be,” cautions Jeff Pool, regional sales representative for DY Concrete Pumps Inc. in Alvarado, Texas. “No. 1 would be seeing the most recent boom inspection report. Then I'd want some type of mechanic’s report – how's the transmission, the gear box, the drive line, the tires. I want to know when the last DOT inspection took place. Finally, how well do you know the seller? I'm the kind of guy you see washing his lawn mower after he mows the lawn – that’s the guy I want to buy a pump from.”The Human EquationThe operator is one of, if not the most, important factors to consider. When the equipment arrives on your job, it’s the most dangerous time of day, says ACPA Executive Director Christi Collins. Certification is mandated by the American Society of Mechanical Engineers and ACPA is the only third party that can provide written assessment and certification, which is required by many public project owners.“Make sure you have an operator who is familiar with that equipment and has been safety trained,” Collins says. “A really good, trained operator who’s in command of the pour can be the contractor’s best friend.”And experience cannot be artificially expedited. In other words, an operator who knows how to set up and operate smaller booms cannot be instantly graduated to the 50-plus-meter classes overnight.Better Safe than DeadIf that sounds severe, then mission accomplished. Gaze for a moment at the most common, and often fatal, hazards:Hose whipping, caused by improper affixing of metal devices at the end of the pump’s flexible hose outlet to control flow. If air builds up, causing the hose to literally whip out of control, a blow to the head can be deadly.Operator distraction – e.g. cell phone usage while pumping.Hitting overhead power lines. You put lives in jeopardy if you go against the operator’s advice to set up away from overhead obstructions.Tipping of the machine due to poor jobsite evaluation and improper outrigger stabilizing.For obviously good reasons, manufacturers build in safety features. Be certain to check for:Emergency electrical shutoffs (E-stops).One-side support allows the operator to set up outriggers on just one side of the pump truck in very confined workspaces. The machine will determine the safe range for the boom’s movement and, if crossed, an alarm will sound followed by shutdown if the operator continues to cross out of the safe parameter.Hopper grate switch disables the machine when grate is opened.Boom tip shut-off valve prevents hose whipping. (see Con Forms video)Get The Right Features for Your ApplicationReach. A top priority is the reach of the pump’s boom. But before you rush to bring out a 39-meter or larger, make the outrigger spread or footprint an equally high consideration. Every manufacturer has working range drawings, most likely available on their websites.Folding configurations. What you choose all comes down to geography. Here’s a simplistic summary of sources’ explanations:Roll-and-fold is ideal for wide, open spaces with no overhead obstructions because, generally speaking, that’s what you’ll need to unfold this boom. The sections fold under one another in a wide curling fashion and, while unfolding, roll out toward the pour.Z and Double Zs work like an accordion. They go up and into tight openings like windows or up and then lower, like over water and then under a viaduct.RZ, also known as multifold, is a combination of roll-and-fold and Z.With all three options, the popular pumping style called A-framing is doable – extending two sections up and sections three and four down, for example.Remote controls. All buttons and joysticks are pretty universal, so operators will find the same functionality from brand to brand.Handling different mixes. Concrete composition is a necessary discussion between pumping contractor and ready-mix producer well ahead of time. Geography plays a big role in the raw material used in the mix and how much pressure it’ll require.“Harsh limestone, gap graded sand are common issues with mixes that are difficult to pump,” says O’Malley. “Lightweight concrete can present difficulties, too, as the lightweight aggregate can absorb moisture while pumping.”Weight. The heavier the equipment, the higher the permitting costs. Manufacturers are trying to help by reducing machine weight without compromising reach, performance, and structural integrity.However, Liebherr’s Wright considers this an understandable but questionable response. Taking away metal to make a lighter boom pump is a safety issue that potentially threatens the equipment’s structural integrity.“A pump is sitting there shoving rock through pipe and it’s a very violent action – and the boom is taking all those shocks and everything as it’s moving through,” says Wright. “It takes its toll.”He thinks manufacturers should make the machine what it needs to be rather than being influenced by a market trying to avoid states’ weight-driven revenue mechanisms – which he says do not apply to cranes.Technology. Computer brains are now included in some brands that, much like your automobile, assist with diagnostic troubleshooting. But there are polar-opposite preferences about how much of this is desired by end users, so the amount of electronic sophistication varies among the brands.Bottom line: Concrete wants to harden and doesn’t care if your pump is having a failure. When the operator needs a quick fix, consider what his comfort level will be with more or less computerization.What to Know About MaintenanceThe pummeling boom pumps endure points to the obvious realization this equipment needs regular, meticulous maintenance regardless of which end of the price and features spectrum it’s on. If you can’t find time to change the oil, you’ll have plenty of time on your hands when the pump needs a new engine.Because boom pumps are sold from the factory as opposed to dealerships, equipment owners do most of their own maintenance and service. Help from the manufacturer should be just a phone call away, and you’ll want some assurance about where their traveling mechanics are based, as well as the speed with which the company will get you any parts you need. Be sure to identify who your local trained technicians are if you don’t have one on the payroll.Here’s what sources recommend to extend machine life:Weekly greasing by hand instead of an auto-greaser gives you the chance to discover problems before they turn catastrophic.Stock common wear parts – pipe, elbows, pistons, various moveable parts in the hopper.Operators who force sharper, rougher mix too quickly wear out pipes, parts, and pieces faster.Lots of things to consider when choosing the best boom pump unit for the application. Adjustable Forms’ Lindquist made it clear that having a good relationship with your manufacturer is paramount – and the foundation for that is confidence they’ll be there for you long after the sale.

The ACI Constructability Committee (ACI 134) is looking for some stories from contractors, engineers, architects, and others in the industry about constructability (obviously!). Have you seen designs or specifications that made your life difficult--such as rebars that intersect? Have you designed something only to be told it was unbuildable? Have you seen contractors, designers, and specifiers work together to resolve issues that gave the owner a quality structure but at less cost and that simplified construction? We’re looking for stories, both good and bad, that others can benefit from. Tell us about your experience and include a photo if possible. I will work with you to write it all out clearly with the intent of publishing in Concrete International or Concrete Construction in our Constructability Series. 

A well-executed Quality Control program is vital to the success of any precast operation. This Quality Control course will present a number of topics that will build on the National Precast Concrete Association’s Quality Control Manual. Attendees will examine concrete on a microscopic level to learn about the different kinds of pores and the hydration process. Coursework covers aggregate gradation analysis, aggregate moistures, hot and cold temperature concreting, testing for mechanical properties and durability, and analyzing trends in test data. Attendees will learn why water-cement ratio is so critical to concrete properties and the need for frequent testing to assess water absorption and movement in concrete. The Maturity Method will be presented in layman’s terms so that a precaster can accurately assess strength development and timing of manufacturing operations. A scientific calculator is needed for this course.At the conclusion of this course, you will be able to:Explain concepts of porosity and permeability and how they relate to water-cement ratioDescribe the influence of proper aggregate gradation on the long-term durability of concreteDefine variability and decrease it by closely monitoring and evaluating trends in material test dataExplain concepts behind hardened concrete testing methods such as compressive strength testingDescribe potential durability issues such as carbonation, corrosion of reinforcing and freeze-thaw damage, and explain ways to mitigate these issues

The move expands Alley-Cassetty’s reach from 11 to 14 locations in the Southeast, demonstrating its commitment to investing in Middle Tennessee.Masonry material distributors Alley-Cassetty Companies, Inc., announced it has entered into an asset purchase agreement to acquire LoJac Materials, Inc., provider of brick, block and stone. Alley-Cassetty will acquire LoJac’s concrete block manufacturing facilities in Lebanon, Dickson, and a yard in Cookeville, Tenn. Combined with its existing facilities in Gallatin and Murfreesboro, the expanded footprint will improve manufacturing efficiency and capacity to more than 12 million block a year, enabling Alley-Cassetty to inherit manufacturing expertise to improve cost of operations.“It’s important that we identify ways to improve efficiencies in manufacturing and distribution to meet the increased demand in the marketplace,” added Sam Strang, Chief Executive Officer for Alley-Cassetty. “This deal not only does that, but also enhances our mission of delivering high-quality products and services to our customers.”Alley-Cassetty’s acquisition does not include the LoJac name and trademark or other subsidiaries that are not engaged in the masonry products business. It is expected that the agreement between Alley-Cassetty and LoJac Materials will close in January 2019.“This transaction is a natural progression of the Blockworks joint venture that Alley-Cassetty and LoJac entered into 3 years ago” says J.D. Lowery, Chief Executive Officer of LoJac Holdings Corporation, Inc. “It combines the retail and delivery side of both block and brick for greater efficiencies and customer service.” Lowery adds “LoJac is proud of its more than 25 year history and how this transaction will result in transitioning of all the employees related to that division of LoJac’s business.”

The American Concrete Institute expects to publish “ACI 318-19: Building Code Requirements for Structural Concrete,” in 2019. The new edition will be the first since the reorganized format was published in 2014 and will include new and updated code provisions along with updated color illustrations for clarity.ACI expects 318-19 to include new code provisions on topics including transverse reinforcement and shear in wide beams, hanger reinforcement, bi-directional interaction of one-way shear, and reference to ACI certifications. Existing provisions expected to receive significant updates and clarifications include two-way shear strength, ordinary walls, seismic loads, reinforcement detailing, analysis, and numerous materials requirements. Analysis methods for two-way slabs and provisions on shearheads and composite concrete columns are expected to be removed.ACI is publishing the complete draft of the proposed “ACI 318-19: Building Code Requirements for Structural Concrete” for a 45-day public review starting December 21, 2018. Printed and digital formats of the final ACI 318-19 are expected, as well as versions in inch-pound units, SI units, and other languages. ACI 318-19 will be included in the ACI Collection of Concrete Codes, Specifications, and Practices, and educational seminars will begin in fall 2019.

Winter officially arrived on Friday, Dec. 21, 2018, at 5:23 p.m. EST, with the winter solstice marking the official change of seasons. Yet, sneak peeks of wintry conditions hit the Rocky Mountains, northern Plains, Great Lakes, and northern New England as early as October. Significant snows and cold temperatures reached some unlikely places, such as the central and southern Plains, the Texas Panhandle, and parts of the Southeast. Chilly temperatures and a foot of snow snarled traffic and caused widespread power outages on Dec. 9th.“The cold temperatures are just beginning,” states Editor Peter Geiger, Philomath, adding, “while some naysayers tried to throw ice water on our ‘teeth-chattering-cold’ winter forecast, Mother Nature seems to be hard at work ensuring that our predictions are accurate.”According to the official winter outlook from the 2019 Farmers’ Almanac, released in August, the real frigid temperatures don’t arrive until mid-February, especially in the Northeast/New England, Great Lakes, Ohio Valley, Midwest, and Southeast regions.The winter forecast predicts a lot more snow to come, especially for the Great Lakes states, Midwest, and central and northern New England areas. The majority of the snow will fall in January and February. Snowfall totals could reach above normal numbers in the northern and central Rockies and Plains.In the forecast is an unusually snowy and/or wet winter across the Pacific Northwest, Northeast, and Mid-Atlantic States; in these regions, with the temperature hovering just above or just below the freezing mark. Precipitation is likely to fall as either ice, rain, or freezing rain. Significant snowfalls are also predicted for parts of all seven U.S. zones.

As we recover from ringing in the New Year, it’s important to note a few clouds on the horizon that didn’t exist a year – or even six months – ago. The rate of growth in the housing and other construction markets is slowing. Auto sales are flattening after a post-Great Recession boom. Global trade wars have everyone on edge. After years of economic expansion, the “r” word is being tossed around by some Wall Street pundits.America’s industrial and service economies, which have been pinched by tariffs, trade restrictions, and the first whiffs of a slowdown in years, aren’t alone in feeling these economic headwinds.So is the Fed.In early December, the business press reported the Federal Reserve was considering a new, wait-and-see approach after a likely interest-rate increase at the board’s December meeting. The board did indeed raise rates, for the fourth time in 2018, to 2.5%. While that could slow the pace of rate increases this year, officials think the overall direction will continue upward. As they push up their benchmark, they’re becoming less sure how fast they’ll need to act or how far they’ll need to go. They clearly want to assess how the economy is holding up under moves they’ve already made.How they manage this less-predictable approach will depend on the performance of the economy and markets in the weeks ahead. This “data-dependent” strategy could prompt officials to step back from the quarterly hikes they made for most of the last two years. Under the old pattern, the Fed would raise rates at its first quarterly meeting in March. Now, Wall Street doesn’t know what to expect.Recent stock market turbulence hasn’t (much) dented the Fed’s view the economy is on solid footing, with growth strong and unemployment low. But inflation has softened in recent months. Falling oil prices indicate further declines, reducing the Fed’s sense of urgency about raising rates to keep the economy from overheating. If growth or inflation heat up unexpectedly, the Fed could go further than planned. That scenario is very much unexpected given the economy’s current tempo.Nothing could be better for housing, mortgage rates, corporate borrowing, and the general economy as a whole than a pause in interest rate hikes. Be on the lookout for a steady hand from the Fed this year, which could be a timely shot-in-the-arm for the concrete industry as rate hikes take a pause.

The Associated General Contractors of America (AGC) and Sage Construction and Real Estate have released the Contractors Remain Confident About Demand, Worried About Labor Supply: The 2019 Construction Hiring and Business Outlook Report.The outlook was based on survey results from over 1,300 firms from 49 states and the District of Columbia. Varying numbers responded to each question. Contractors of every size answered over 20 questions about their hiring, workforce, business and information technology plans.For all 13 categories of projects surveyed, respondents that expected the market segment to expand exceed those that expect the market to contract. For every segment, between 23 to 32% of respondents expect the dollar volume of projects they compete for to increase. Meanwhile, for all but one segment, between 11 to 16% of respondents foresee less work available in 2019. The difference between the positive and negative responses – the net reading – was between 10 to 17% for every category except multifamily.“Construction executives appear to remain confident about their market prospects for 2019 and plan to add headcount to cope with the added workload,” says Stephen E. Sandherr, the association's chief executive officer. “Even as they are optimistic about growing demand, contractors are concerned about finding qualified workers to execute projects.”Public building construction scored the highest net positive reading of 17%. Three other segments had a 16% net positive: highway, K-12 school, and hospital construction. Projects for federal government agencies, and retail/warehouse/lodging both had a net positive reading of 15%. Water & sewer and transportation facility construction had a net positive reading of 14%.Four categories had a slightly less-positive net reading: private office construction (13%); manufacturing construction (12%); higher education construction (11%) and power construction (10%). The lowest net positive reading was for multifamily residential construction, at 5%. Association officials said this may indicate that multifamily construction has outpaced demand for now in some locations.Nearly four out of five contractors (79%) plan to increase their workforce this year, up from 75% at the start of 2018 and 73% at the start of 2017. However, just under half of firms report their expansion plans will only increase the size of their firm by 10% or less. About one-fifth of respondents plan to increase headcount by 11 to 25%. Only 7% of respondents plan to increase employment by more than 25%.Despite firms’ plans to expand headcount, 78% report they are having a hard time filling salaried and hourly craft positions. That share was down slightly from 83% at the start of 2018. In addition, 42% expect it will continue to be hard to hire in the next 12 months and 26% expect that it will become harder to hire in 2019.These labor shortages are having an impact on construction costs and project schedules, association officials noted. One-third of respondents report that staffing challenges drove costs higher than anticipated. In reaction, 37% of firms are putting higher prices into new bids and contracts. Similarly, 34% report projects have taken longer than they anticipated.Firms continue to raise pay and provide bonuses and benefits in response to labor shortages. 59% of firms report they increased base pay rates. 29% provided incentives and/or bonuses. 24% of firms increased contributions or improved employee benefits to cope with workforce shortages.Many firms are also investing more in training programs. 63% report a plan to increase investments in training and development in 2019, up from 52%. Large firms are more likely to do so, with 71% of companies with more than $500 million in revenue saying they plan to increase investments in training, compared with 59% of firms with $50 million or less in revenue.“As growing demand and labor shortages force contractors to do more with less, many firms are increasing their investments in labor-saving technologies and techniques like building information modeling, lean construction and robotics,” says Ken Simonson, the association's chief economist. He noted that 32% of respondents report their firms are using methods to reduce onsite worktime, including lean construction, virtual construction techniques or off-site prefabrication. 28% are investing in labor-saving equipment, including drones, robots and 3-D printers.42% of respondents will increase their IT investments in 2019. 30% of these firms plan to increase their investments in project and document management software. 31% show comfort with moving information to the cloud, compared with 24% last year. Even as firms embrace information technology, 26% report their biggest IT challenge is a lack of time necessary to implement new systems.Though contractors are optimistic about demand for construction services in 2019, the outlook is based on responses that were provided before the partial federal government shutdown and when a halt to pending tariffs on a wide range of Chinese goods had been announced.“This means that if Washington officials can’t find a way to work together to continue needed regulatory reforms and enact new infrastructure funding, many contractors’ more optimistic expectations will not be met,” Sandherr says. “And many contractors will be squeezed by growing costs for materials at a time when an expanded trade war will likely undermine private-sector demand if American and Chinese officials cannot resolve their trade disputes.”AGC is committed to making sure Washington leaders act to support continued economic growth in 2019. The association will continue to advocate for new infrastructure investments, regulatory reforms, federal funding for career and technical education, and comprehensive immigration reform.“Our goal is to ensure that the construction industry expands in 2019 amid growing demand for new projects and an infusion of new and qualified workers,” Sandherr says. “If that happens, the entire economy will benefit.”

The Catalina Island Conservancy has selected the Pentagon's Innovative Readiness Training program to complete the replacement of the 3,000 foot-long Catalina Runway 4/22, a project valued at over $5 million. The project is one of the largest concrete endeavors for the Marines, who typically do small scale repair work. To prepare, two concrete pads were installed to help Marines properly learn how to work with concrete and rebar. Workers will begin pouring concrete in mid-January and expect to complete to runway in three months.The Pentagon’s Innovative Readiness Training program started 25 years ago to bolster military readiness while helping local needs. Communities, including remote Native American and Alaska Native villages, request medical, veterinary, cybersecurity, construction or engineering support. Missions often are assigned to reserve units.

 The Post-Tensioning Institute (PTI) has announced the selection of Anthony (Tony) Johnson, P.E., as the organization’s new Executive Director, effective Jan. 2.Johnson was a member of the Concrete Reinforcing Steel Institute’s (CRSI) Regional Manager team, responsible for providing technical assistance, outreach, and education to engineers, architects, owners, contractors, as well as student groups.Johnson graduated from the Michigan State University Eli Broad Graduate School of Management where he attained a Master of Business Administration degree. He graduated with honors from the University of Wollongong (Australia) with a Bachelor of Engineering in Civil Engineering.“The addition of Tony as the new Executive Director is consistent with the Institute’s strategic plan of growing, evolving, and improving both the organization and the industry,” says Todd Stevens, PTI President. “With Tony’s extensive industry association experience at the helm, along with his savviness in technical marketing, member relations, and market development, I am confident he will lead the organization to be more positively impactful in the industry than ever before.”Johnson graduated from the Michigan State University Eli Broad Graduate School of Management where he attained a Master of Business Administration degree. He graduated with honors from the University of Wollongong (Australia) with a Bachelor of Engineering in Civil Engineering.PTI, in its 43rd year, leads the industry as the foremost source for resources relating to the post-tensioning market. As the Institute’s new Executive Director, Johnson will focus on supporting and growing Institute programs, providing a superior member relations program, and increasing the value of PTI’s products and services for members and prospective members alike.“Over the past 43 years, PTI has built an outstanding reputation of providing excellent education, certification programs, codes and standards, and of promoting the industry and supporting research,” says Stevens. “We plan on moving this agenda forward in 2019 and beyond.”

Charah Solutions, Inc. provider of environmental and maintenance services to the power generation industry, has installed its proprietary fly ash beneficiation technology at the company’s Sulphur, Louisiana terminal. The new MP618 Multi-Process technology reduces loss on ignition (LOI), ammonia, activated carbon, and moisture in fly ash.The technology allows for beneficiation of both wet and dry fly to provide concrete product producers and builders with a reliable source of high-quality Class F fly ash in the greater Lake Charles / Sulphur region. The Sulphur terminal is Charah Solutions’ second barge-supplied location in Southern Louisiana. Its LaPlace, Louisiana, terminal currently serves customers in Louisiana, Mississippi, and Alabama.“The launch of the MP618 technology is a significant milestone for Charah Solutions and a game changer for the beneficiation of fly ash,” says Charles Price, President and CEO of Charah Solutions. “Our utility customers now have an innovative, cost-effective solution that doesn’t require a significant capital investment or increase costs to rate payers. Additionally, we now expect to be able to provide a more reliable stream of fly ash to our customers. The launch of this facility highlights the importance of our acquisition of SCB International last year, and is the first of many facilities we expect to install nationwide.”The MP618 technology has low cost profile, an efficient footprint with self-contained environmental controls that can be deployed in months versus years, and a modular design that can be scaled up or down to increase production based on market demand.With the functionality to process both wet and dry fly ash, the MP618 technology can be installed at both operating and non-operating power plants, regardless of whether the fly ash is current production or legacy ash stored in ponds or landfills. The technology also allows for the processing of kiln dust to remove mercury for emissions regulations compliance.MP618 is expected to enhance Charah Solutions’ MultiSource materials network, a unique distribution system of more than 30 nationwide sourcing locations, and improve the company’s ability to provide a continuous and reliable supply of supplementary cementitious materials for ready-mix concrete producers and other customers throughout the U.S.

By 2025, over 50% of building materials can be expected to contain nanomaterials, as industries embrace their lighter, stronger, and energy efficient benefits. For cementitious materials, adding nano-silica can reduce the calcium-silicate-hydrate (C-S-H) reaction caused by leaching of calcium into the water; the material blocks water diffusion, improving the durability of the cement. Carbon nanotubes increase compressive strength of mortar and change its electrical properties, which can aid in damage detection.

With only a week to go before the 2019 World of Concrete, everyone is scrambling to set up their schedule for the show. I am, of course, looking forward most to the Concrete Polishing Luncheon on Tuesday and the Concrete Slabs Luncheon on Wednesday and I’ve had great conversations with the panelists at each luncheon over the past week.For Polishing, we will explore the use of clarity meters to measure the surface appearance. “There’s no point in specifying the DOI value for a polished floor if you can’t measure it,” says Pat Harrison with SSI. He feels that this new measuring technology could completely change the concrete polishing industry in the same way that F-numbers changed concrete slabs. The other panelists are Chad Gill, Jennifer Faller, Jim Cuviello, and Darryl Case.At the Quality in Concrete Slabs Luncheon, we’ll also be talking about specifications, but this time related to elevated concrete slabs. What makes sense in a spec? Are F-numbers reasonable? “The electricians and plumbers don’t like to drill cores anymore because of the silica dust requirements,” says Stevie Ray Lloyd with Lloyd Concrete Services, “so they use penetration sleeves that we have to place concrete around. That makes it impossible to run trowels and difficult to measure the flatness.” So, then, how can a contractor achieve an FF 35? Join Lloyd, Chris Tull, Walt Flood, and Matt Poppoff to explore this issue.A new event that should be fun is the Concrete Start-Up Zone that will be in the North Hall, N153. Sponsored by the ACI Foundation’s Strategic Development Council, the Start-Up Zone will showcase emerging technologies and innovations. A key participant will be NASA’s 3-D Printed Habitat Challenge, where teams will compete to create sustainable housing solutions for Earth, the Moon, Mars and beyond. 3-D printing of concrete could be in your future!

The Advance Civil Engineering Materials Research Lab (ACE-MRL) from Ann Arbor's University of Michigan, has developed a bendable concrete that could make infrastructure safer and longer lasting. Drawing inspiration from the brick-like structure found on the inside of a shell, researchers devised an engineered cementitious composite (ECC) which contains tiny fibers dispersed within. The fibers create slippages that allow the concrete to bend.ECC can deform up to 3 to 5% in tension before it fails, which gives it 300 to 500 times more tensile strain capacity than normal concrete. This allows a slab of it to undergo a lot of bending without fracturing into pieces, earning it the nickname of flexible or bendable concrete.

Shanghai is now home to the world's longest 3D-printed concrete pedestrian bridge. The 86-foot-long bridge is just under 12 feet thick and features a single arch with ribbon-like handrails. 44 hollow concrete units were printed from composite materials containing polyethylene fiber concrete; the handrails required 68. Two robotic arms completed the parts over the course of 450 hours.The streamlined process is estimated to have produced savings of 33% when compared to a more conventional construction process – attributed mainly to the elimination of templates and reinforcing bars.

Fleet managers and procurement teams are charged with designing reliable, functional work trucks capable of undergoing the stresses of the vocational market and occupational work environment. No matter what your role on the design team (specification writer, supplier, upfitter, or final decision-maker), it is imperative to understand the work mission of these specialized vehicles.What defines a work mission? It starts with supporting an organization’s mission statement and directly influences operations at the fleet level. The work mission involves providing the right tools that maximize efficiency and reliability, while operating in extreme duty cycles and environmental conditions. Before anyone in the industry can design vehicles to outlast the rigors of the work environment, the first step is gaining full awareness of mission requirements and available alternatives. Examples include operator feedback, geographic location of the truck, fuel type/availability and payload requirements.When designing and purchasing vocational vehicles, there are several options available in both procurement and design aspects. The route a fleet professional chooses can directly influence overall unit cost. With some solid data collection, historical information can become a great source of insight when looking for ways to control cost.In addition, it’s necessary to know that cost control includes components that are both direct (acquisition, operating and maintenance) and indirect (temporary replacement vehicles and underutilized operator resources). Reliability and utilization are some of the most critical aspects of cost control. Vehicles that are underutilized are not necessarily unneeded, but it is essential for the fleet operator/owner to be able to make a clear value assessment.In terms of reliability, consider whether or not the vehicle is properly designed to survive the rigors of the work mission from the start. Reliability is a critical aspect of all fleet-related activities. Unavailable tools lead to fleet ineffectiveness, including loss of productivity and, in some cases, direct company revenue. Even still, reliability can be the focal point of cost control for fleet operations. Minimizing out-of-service events can ensure a fleet is more reliable and augment effectiveness of field personnel. Having a more reliable fleet translates into fewer vehicles needed to fulfill operations, allowing you to examine and fine-tune utilization.Connecting Drive and Duty Cycle to the Work EnvironmentDrive and duty cycle go hand in hand when designing work trucks. Drive cycles provide data on how vehicles are used. These data points include maximum/average speed, idle time, engine off time and power export time (PTO). Duty cycles give fleet managers insight into how much (as opposed to how) a vehicle is being used, including information like days per week or measurement cycle of use, hours per shift/day, total distance traveled, and engine load profiles. Evaluating both of these data clusters while interacting with the operational environmentis key.The operational environment encompasses geographic areas — either local, regional or large territories. Weather conditions can influence vehicle design: Are your vehicles operating in snowy or salty regions that require corrosion protection? Are they functioning in mountainous areas that demand starting gradeability and present powertrain concerns? Identifying your fleet’s unique operating needs and communicating with the stakeholders involved in your vehicle design are significant priorities.Once properly designed, standardizing your vehicles can support reliability. Having standardized vehicles makes it easier to stock replacement parts, develop well-trained maintenance crews, and create safe and effective upkeep routines. Having several one-offs or different standards may be a way to reduce initial acquisition cost but ultimately increases maintenance expenses and potentially extends downtime.Regulations and Safety Features Reduce the Bottom LineConforming to regulations is nonnegotiable when designing vehicles. However, requirements are constantly changing, and it can be challenging for fleet managers to keep up with the latest rules, which often evolve based on experience. For example, prior to the year 2001, no states had regulations geared toward talking on mobile devices while operating motor vehicles. Data shows cellular activities increase driver distraction, and operators are currently advised to avoid using these devices while underway.Another more recent regulation was enacted to improve rearview visibility. Full FMVSS 111 rear visibility conformance in the U.S. — which includes requirements for field of view, image size, response time, deactivation, durability, default view and linger time — took effect May 1, 2018. This requirement is applicable to vehicles with a 10,000-pound (4,536-kilogram) gross vehicle weight rating or less. The full equivalent regulation in Canada is mandatory starting May 2019 and includes three-wheeled vehicles.Using multiple resources to ensure your designs meet conformance standards is an essential step in the vehicle build process. There are several sources available to fleet stakeholders, including NTEA’s technical services department. Access NTEA resources on this topic at ntea.com/mvss111rearvisibility.Optional safety features should be considered a means to improving long-term vehicle survivability — not just an extra expense. They can add life to vehicles and reduce unrelated costs in the unfortunate event of an incident. Looking at vehicle uptime and reliability, these features often pay for themselves. For example, pre-collision and radar-based cruise control systems can significantly reduce rear-end collisions. Any collision creates downtime, which no operator/owner needs.Overcoming the Information GapWithout proper information, you will, most likely, design a vehicle that is not best suited for the intended task. It’s wise to stop and think about possible factors not yet taken into account. Be willing to ask questions. Engaging the right stakeholders and information sources with thoughtful questions is a valuable part of the process.Two main stakeholders in an effective design are the end user and the maintainer. Good service history with cause analysis improves vehicle design. Once you recognize what your key stakeholder groups contribute, you can better anticipate the work environment. Examining previous breakdowns and failures can indicate unforeseen uses and/or room for improvement.Another valid concern is how much reserve capacity to build into a truck. Running trucks to their design limits (even when the vehicle conforms with regulatory guidelines) will often shorten the effective life, increase maintenance costs and reduce residual values at end of life. As an example of defining capacity reserve, when the user dictates a maximum payload requirement of 5,000 pounds, the specification writer should add some reserve capacity. A good rule of thumb is targeting 85 percent of the vehicle’s rated capacity as the design limit. There are two chief reasons: in general use, operators rarely know how much their specific load weighs relative to vehicle design capacity, and some work circumstances require the ability to carry as large a load as possible. Obviously, too much reserve can be expensive and impractical. To visualize the upper extreme of overdesign, think about using two rear axles though a single rear axle could effectively do the job. Of course, regulatory criteria could call for a second axle even if there’s not a vehicle capacity issue. Frost laws that limit ground pressure provide an excellent example of a design feature unrelated to the need for additional capacity that requires a truck to have a second rear axle.Suppliers can be a wealth of product knowledge. Most likely, they have covered a large territory and have seen many problems and solutions; they are in a position to make suggestions and partner with your organization; and they can be a tremendous resource in building equipment that lasts for years. While it’s tempting to view purchasing a new fleet asset as a transactional event, in reality, your assets need to work reliably for years and (in the case of very expensive specialty equipment), sometimes, more than a decade. In such cases, the supplier becomes a useful partner for the product life. Getting involved in NTEA’s Member Verification Program (MVP) is a great way to connect with valuable industry partners. This program recognizes participating companies in the work truck industry for outstanding business practices and successful implementation of quality standards (find details, including the MVP member directory, at ntea.com/mvp).Controlling the Bottom LineIn summary, fleet equipment is expensive but necessary to transfer your goods and services to your customers. For specialized vocational trucks, this is an even more important realization. Using thoughtful, well-researched vehicles designed with input from key stakeholders, you can minimize maintenance costs and out-of-service time. To optimize your fleet, be cognizant of the work mission, drive requirements and environmental constraints. Accounting for these considerations and partnering with leading industry suppliers can improve fleet effectiveness and your company’s bottom line.

Engineers around the world have developed alternatives to widely used building materials with reduced harmful environmental impacts. Of the top five innovative materials, two are possible substitutes for cement; the most widely used manmade material in the world also responsible for 5% of human-generated CO2 emissions each year.Scientists at Rice University in Texas have developed a 'programmable' cement able to be controlled by negatively and postively charged surfactants (compounds that lower surface tension). The result is a less porous concrete that is significantly stronger. North Carolina building materials company bioMASON has developed cement bricks that grow when fed with nutrient-rich water and require less energy to create than standard cement bricks.

You’ve probably heard that the construction industry has not increased its productivity over the past 20 years. That construction remains stuck in a rut of its own making. New ideas in managing projects are rejected, new materials are ignored, and workers refuse to change the way they work. I’m here to tell you that it doesn’t have to be that way and some contractors are indeed changing and finding ways to increase both quality and margins.But let’s be clear, the construction industry is entering (or is already in) a period of disruption. Operating your business in the same way you have in the past is going to lead to already slim margins shrinking past zero. FMI asked contractors about change: 58% expect more change in the next 5 years than in the last 50 years combined.So you’re probably saying to yourself, OK, I can handle change but knowing what to change and how to change it is the key. Change is hard, and many companies have failed due to too much change, so caution is smart. Over the next few months, Hanley Wood will present Building Forward, a web site dedicated to analyzing the disruptive changes in labor and productivity that are transforming construction today. Take a look and keep coming back as we show ways to change and adapt that others have found successful.

According to Associated General Contractors of America, 70% of construction firms report difficulty finding qualified tradespeople, with concrete workers topping the list. Lack of skilled labor and construction inefficiency are adding extra hurdles, time, and expense to many projects just when owners increasingly demand fast-track completion to minimize disruption and economic impact. Even the slightest delay can significantly impact your bottom line.To maintain profitability, many contractors are embracing high-tech materials and methods to improve productivity. One such solution is a ready-mix concrete that develops high mechanical resistance quickly after pouring, enabling contractors to rotate forms, load structural elements, and open pavements to traffic three to five times faster than standard concrete.The mix delivers the same strength ordinary mixes gain at 28 days in 48, 24, 15, 6, or 4 hours. The product’s fluid consistency allows for transportation and usage for two hours without affecting handling, making it easy to use in all types of vertical and horizontal applications.Formwork for walls, columns, and other vertical jobs can be removed after 4 hours instead of 12 hours to 20 hours, increasing productivity by doubling daily formwork operations. Horizontal work such as floor slabs, sidewalks, parking lots, and roads can reopen to traffic within 24 hours instead of the seven days typically required by other high-early-strength mixes.Customized Fast-Track ConcreteCombining two hours of workability with rapid-early-strength gain is a significant technological achievement. Developed by LafargeHolcim US, Rapidforce is made possible by a blend of accelerating and slump-retaining admixtures. Designed in optimum proportions based on local raw material characterization, every customized mix is rigorously tested in LafargeHolcim’s quality-control laboratories to achieve targeted performance properties specific to application type.These advanced early-strength mixes are providing significant return on investment in a wide variety of projects across the country where speed of construction is critical.When a portion of Canal Street in New Orleans collapsed in 2016, a massive sinkhole opened above a long-abandoned expressway tunnel. Although the tunnel had remained structurally sound, the temporary timber end walls left in place had deteriorated after decades of water intrusion.One of the busiest thoroughfares used by tourists, Canal Street is home to many retail stores, hotels, restaurants, and entertainment venues. The mayor quickly declared a state of emergency.The city set the repair schedule at 90 days and offered financial incentives for early completion. To accelerate repairs, general contractor Hard Rock Construction of Harvey, Louisiana, needed concrete that would achieve rapid strength gain and flow easily through a 2-inch line running hundreds of feet into the sinkhole. LafargeHolcim supplied 5,000 cubic yards of a custom-designed Rapidforce mix that eased placement and achieved 4,000 psi within 24 hours. The road was repaired with a mix designed to achieve 3,000 psi within 24 hours.Repairs involved building a new support wall from within the sinkhole and resurfacing the damaged pavement. Crews poured a 4-foot-high footing and then built masonry walls on top, filling every block with the Rapidforce mix. Using the masonry walls as permanent forms, they sealed the tunnel by installing a 26-inch-thick cast-in-place reinforced Rapidforce wall.Repairs were completed in 39 days—months earlier than expected—for $3.5 million on a job initially budgeted at $5 million. “Rapidforce made a tremendous contribution,” says Hard Rock Construction Project Manager Chris McLellan.“With our economy struggling, the last thing we needed was to make it more complicated to get into and out of our businesses,” says a local business owner. “My employees and other shop owners are grateful the problem was resolved quickly and efficiently.”TruSeal America, an asphalt, concrete, and seal-coating contractor in Inver Grove Heights, Minnesota, needed to repave two lanes at Holiday Gas Station’s busy location in Savage, Minnesota. Normally, the company would use a standard high-early-strength mix that cures in seven days and phased construction to minimize construction impacts.Instead, to speed things up, Truseal America used a Rapidforce mix designed to deliver 28-day strength in 4 hours to 48 hours while maintaining the design slump throughout the process.For a busy retail establishment, reopening to traffic even a day sooner than expected is a significant economic benefit.“Rapidforce helped us complete a two-week project in 24 hours, saving significant labor costs,” says TruSeal America Owner Steve Tjornhom. “And our customer was happy to see their lanes were open for business in only one day.”To help alleviate a critical parking shortage at Buffalo Niagara Medical Campus (BNMC) in New York, the City of Buffalo announced plans for accelerated construction of a new garage. The structure had to be built before a new medical school and children’s hospital opened, bringing thousands of students, employees, and patients.Located in the heart of the emerging medical campus, the eight-level parking garage has more than 1,900 spaces and consists of long-span, cast-in-place, post-tensioned beams and deck slabs to provide column-free drive aisles. The project required a mix that would gain an early strength of 3,000 psi at 48 hours, for releasing the post-tensioning tendons, and a final specified design strength of 5,000 psi at 28 days.To meet the deadline and achieve rapid strength gain, LafargeHolcim developed and supplied more than 18,000 cubic yards of a customized mix for all structural elements. Designed with a blended cement containing silica fume and slag to achieve high strength and low permeability, the concrete allowed for easier placement and consistently achieved the specified early-strength gain within two days.Rapidforce delivered the specified 28-day strength of 5,000 psi in seven days, which allowed heavy equipment to be put on the concrete and work to continue up to higher levels ahead of schedule. The mix’s ability to achieve and maintain a high slump also resulted in nice, smooth finishes on the columns with minimal vibration, a huge benefit in terms of time and labor cost savings.Construction finished weeks ahead of the new facilities’ scheduled opening.Traffic never stops moving through the U.S. Postal Service (USPS) Network Distribution Center in Capitol Heights, Maryland. When it was time to rebuild the severely deteriorated pavement in front of loading docks, it was imperative to complete the new pads as quickly as possible.Chilar Construction of Beltsville, Maryland, considered a high-early-strength mix that would require three days to cure and gain proper strength, but USPS facility managers demanded an even quicker turnaround to minimize service disruptions: 24 hours.The mix needed to achieve a specified strength of 5,000 psi. The old concrete was removed and replaced with 10-inch-thick pavement. Five to six docks were done at a time so fleets could continue delivering mail during construction.Aggregate Industries supplied more than 1,500 cubic yards of a Rapidforce mix that delivered a 5,000-psi compressive strength in 24 hours. The project was completed a month ahead of schedule in 24 days.“Like clockwork, we were removing traffic cones from the new pavement every 24 hours to allow the trucks to back up into the docks,” says Chilar Construction President Juan Calderon. “USPS was very happy about getting the work done so quickly, and it benefitted us with less labor time on the jobsite.”One Dalton Street tower is a notable addition to Boston’s skyline. Soon to be New England’s tallest residential skyscraper, the 60-story architectural landmark consumed 70,000 cubic yards of concrete.Each floor was a 11,500-square-foot slab. The schedule required placing two floors each week. Specified strength gain was 24 hours.“We needed an advanced high-early-strength concrete that would allow us to remove the formwork in a short amount of time and high-strength, self-consolidating mixes that would flow easily through and consolidate around congested reinforcement in the core walls and the uniquely tapered perimeter columns,” says Mike Curtis, president of G&C Concrete Construction in Haverhill, Massachusetts.Like the eight-story parking garage in New York, Aggregate Industries supplied a Rapidforce mix that contained silica fume and fly ash. For the heavily reinforced columns and walls, G&C Concrete relied on high-strength Agileflow self-consolidating mixes to speed up pouring and meet the challenging performance criteria.“The Rapidforce hit its high-early-strength consistently so we could strip out the forms early,” Curtis says. “The Agileflow eliminated the need for vibration in the heavy-rebar applications, and the column finishes were nice and smooth.”

The Decorative Concrete Council (DCC), a specialty council of the American Society of Concrete Contractors (ASCC), St. Louis, Mo., has announced the winners of its 11th annual Decorative Concrete Awards competition.Bullion Coatings of Katy, Texas won the WOW! Award, best overall project, for Sawmill Lakes Recreation Center Splashpad. Bullion used Sundek Classic Texture and Sundek Sun Coat for this splashpad which was designed to mimic the Louisiana swamps with stars reflecting in the water. Fourteen custom colors, 400 stars, six constellations, three template trees, a four-color grassy area, and a four-color template moon were used in the design by TBG Partners, Houston. The Sawmill Lakes Splashpad is in Sienna Plantation, Missouri City, Texas.Other winners include:Architectural Cast-in-Place Concrete (over 5,000 square feet)Baker Concrete, Monroe, Ohio, for National Veterans Memorial and MuseumCast-In-Place Stamped (over 5,000 square feet)Winner: Bomanite Malaysia Sdn Bhd, Georgetown, Penang, for Karpal Singh Promenade2nd place: Greystone Masonry, Stafford, Va., for Garcia ResidenceCast-In-Place Stamped (under 5,000 square feet)Winner: Salzano Custom Concrete, Aldie, Va., for Royal River Front2nd Place: Shepherd’s Construction Co., Anderson, Ind., for Campbell ResidenceCast-In-Place Special Finishes (over 5,000 square feet)Winner: Trademark Concrete Systems, Oxnard, Calif., for 888 at Grand Hope Park2nd Place: LaRusso Concrete, Wilsonville, Ore., for Market of ChoiceCast-In-Place Special Finishes (under 5,000 square feet)Winner: T.B. Penick & Sons, San Diego, for Miller Park Amphitheater Splash Pad2nd Place: T.B. Penick & Sons for Kona KaiNew Category: Cementitious Overlays (over 5,000 square feet)Winner: Sundek, Arlington, Texas, for Celebrino Event Center2nd Place: T.B. Penick & Sons, San Diego, for 33 TehamaNew Category: Cementitious Overlays (under 5,000 square feet)Winner: Intricate Concrete, Bay Area, Mich., for Faux Wood Porch2nd Place: Colorado Hardscapes, Denver, for Belleview Block BConcrete Artistry (over 5,000 square feet)Winner: Bomanite Malaysia Sdn Bhd, Georgetown, Penang, for Albukhary International University2nd Place: T.B. Penick & Sons, San Diego, for 33 TehamaConcrete Artistry (under 5,000 square feet)Winner: Bullion Coatings, Katy, Texas, for Sawmill Lakes Recreation Center Splash Pad2nd Place: T.B. Penick & Sons, San Diego, for Las Vegas Showgirls SignMultiple Applications (over 5,000 square feet)Winner: Bomanite Malaysia Sdn Bhd, Georgetown, Penang, for Albukhary International University2nd Place: Bomanite Malaysia Sdn Bhd for The Light LinearMultiple Applications (under 5,000 square feet)Winner: T.B Penick & Sons, San Diego, for Miller Park Amphitheater Splash Pad2nd Place: Alchemy Concrete, Nelsonville, Wis., for Berard Pool, Deck & PatioProject VideoWinner: T.B. Penick & Sons, San Diego, for Fern Street Public Art Project2nd Place: Decorative Concrete of Virginia, Lynchburg, for Academy Center of the ArtsPolished (over 5,000 square feet)Winner:Hyde Concrete, Pasadena, Md., for TechSpace2nd Place: Trademark Concrete Systems, Oxnard, Calif., for The Jeremy HotelPolished(under 5,000 square feet)Winner: Scout’s Custom Concrete, Greensboro, N.C., for Bennett, N.C., Garage/Man Cave2nd Place: Industrial Caulk and Seal, Delta, Pa., for DINFOSStained (over 5,000 square feet)Hyde Concrete, Pasadena, Md., for TechSpaceStained (under 5,000 square feet)Winner: T.B. Penick & Sons, San Diego, for Las Vegas Showgirls Sign2nd Place: Little Feet Concrete, Lexington, Ky., for Kalinyak FloorVertical/Facades (over 5,000 square feet)Winner: Consigli Construction Co., Milford, Mass., for Wellesley College Pendleton Hall West Addition2nd Place: T.B. Penick & Sons, San Diego, for Torrey PointVertical/Facades (under 5,000 square feet)Winner: Modern Concrete, East Providence, R.I., for Harbor View Residence2nd Place: Intricate Concrete, Bay Area, Mich., for Faux Stone WallThe DCC is composed of contractors, manufacturers and suppliers of decorative concrete products. The Council is dedicated to improving the technical and business expertise of the contractors that pursue this specialty market. 

Build with Strength, a coalition of the National Ready Mixed Concrete Association consisting of civic organizations, fire service professionals, architects, engineers and industry experts committed to enacting safer and more sustainable building standards welcomes a new member of the coalition, the Mayfair Civic Association.Mayfair Civic Association is a community-based nonprofit organization in Northeast Philadelphia whose mission is to promote the Mayfair community as a “great place to live and work.” They conduct and develop programs that serve as a bridge between business, culture, economic development and residents, with a keen focus on programming for families, children and seniors.“The people of Mayfair, and Philadelphia as a whole, deserve to live and work in safe buildings,” says Kevin Leonard, Vice President of Mayfair Civic Association, “and as an organization, we understand from a programmatic perspective how stronger building codes can drive businesses and residents to invest in a community long-term.”Urban population centers like Philadelphia have an opportunity to vastly improve safety standards for new construction and ensure that current and incoming residents alike have access to fire-safe buildings. Build with Strength as a coalition works with organizations like Mayfair Civic Association to advocate for stronger building codes that include the use of noncombustible materials.“Working alongside Mayfair Civic Association allows us greater access to local residents and community leaders, providing valuable insight into the needs of Philadelphia,” says Kevin Lawlor, a spokesperson for Build with Strength. “There is undoubtedly a troubling trend of weakened building codes across the United States, and as a coalition we are dedicated to strengthening those standards for the benefit of neighborhoods like Mayfair.”

According to a study from the Department of Public Health at the University of Massachusetts Lowell, workers at demolition, crushing, and bridge repair sites in the Massachusetts area were sometimes exposed to as much as 10 times the permissible exposure limit (PEL) of silica dust. The bridge repair site had the highest levels at 527 micrograms per cubic meter of air, while workers operating crushing machine tenders had an exposure of 93.3 micrograms, and operating engineers averaged 17 micrograms per cubic meter of air. OSHA's silica regulation established a PEL limit of 50 micrograms per cubic meter.Controlling or reducing silica exposure below OSHA’s PEL “remains challenging for chipping workers and crushing machine tenders. Even with the use of dust suppression controls, respiratory protection may be required for various tasks,” the researchers said. They recommend that employers provide additional respiratory safeguards for these workers.

In the Netherlands, 60 miles east of Amsterdam, the small village of Teuge will soon be home to the first 3D-printed concrete meeting space titled, The Meeting Factory. The 1,000-square-foot structure is one of many projects starting to come together through this process; 3D-printing is lauded as a faster, environmentally-friendly, and more affordable method of construction. With the technology still maturing and the process trying to reconcile concerns with building codes, the growth in popularity has been slow to come. However, many projects have proven the efficacy of large-scale 3D-printed concrete structures.The U.S. Marine Corps has 3D-printed a 500-square-foot concrete barracks hut, with an eye to robots eventually building military structures on demand. And last month, two companies announced a 3D-printed homebuilding system called We Print Houses, which they intend to license to builders and contractors around the U.S.

Even with BIM becoming more prevalent, it’s not often that the same 3D model is used throughout a project — from estimating to the field. For decades, 2D was the industry standard and even with more projects moving to 3D, we still see a fair amount of re-work in shifting between 2D drawings and 3D models. When this happens, we lose the ability to visualize and the resulting re-work is time-consuming and opens up the potential for errors which, in essence, defeats the purpose of BIM.A Shift in Perspective In 2016, we were computer drafting our design drawings with AutoCAD. BIM was intriguing to our team, but we weren’t ready to make a commitment. It was during a design-build meeting on an industrial project that year when everything shifted. During a meeting to work with the project team on the design, we worked from a 3D model provided by the engineer. We didn’t open the plans once, yet the model gave me a really good understanding of the job. This was unexpected. I always thought that because we aren’t designers, the 3D model doesn’t hold a lot of value for our customers. But on this project I realized that the visual nature of BIM can help to ensure that crews in the field understand exactly what they're building. Most of the crews and project teams in this business are visual, so telling them how to build something is one thing but showing them is completely different. I walked away from that meeting ready to approach BIM with a different mindset.Putting BIM to Work With this new outlook, we started to look at all the places in our business where BIM could add value. We began exploring BIM by using Trimble’s BIM software, Tekla Structures, to automate formwork design which, at the time, was done with AutoCAD or by hand.Our goal was more automatic and quickly designed formwork with enough detail to eliminate or reduce the 2D plans that we provided to crews in the field. For example, specifically showing the type of clamp and illustrating the reason behind it so the crew could understand it visually.Using the pour and concrete geometry in the Tekla Structures model, along with interactive and automated tools, allow us to create realistic formwork models for planning and optimizing our formwork operations in far less time. Not only do we have 3D formwork models to share with the field crews, we also have detailed drawings that are created from the model by pour and a quantity take-off for the formwork needed to build the structure by pour.We recently did a side-by-side comparison of a Tekla Structures model and 2D drawing. The goal was to get a basic sequence that we could make visual by importing into Tekla Structures. Modeling the entire structure in Tekla Structures, we broke it down into 80 pours that coincided with the engineer’s plans. We created a sequence for the most efficient way to carry out those pours across the five crews working on the project and were able to share a video sequence of which pour each crew would work on and when.Showing that we had thought through the process and had a plan that was based on a constructible 3D model was powerful. In parallel, we carried out the same process on paper. We then put 2D sequence into a schedule and imported it into Tekla Structures. The visual sequencing showed us that there were errors in our 2D drawings. On paper we couldn’t see the problems in sequencing, where one pour should start after another. But with the 3D model, we could easily visualize the order in which pours needed to happen. In most cases, we will continue to use a 2D drawing to get a desired flow of concrete placements and then use Tekla to find and correct errors.In the FieldWith that success behind us, our goal was to push the 3D formwork models to crew supervisors for use in the field. Today, we create highly-detailed work packages for each crew’s daily assignments. Using Trimble’s collaboration platform, Trimble Connect, we provide crews in the field with a constructible 3D Tekla Structures model that they can spin around on their iPad and look at from any angle, directly from the job site. Sharing a model with as-built information that is truly constructible accelerates communication with the field crews, allows them to visualize the formwork and makes the entire process much more efficient.Model-Based EstimatingWe’ve recently explored using the 3D model to double check estimates. In today’s competitive market, estimators are required to work fast. It’s not unheard of for a number to be transposed or entered incorrectly. Recently, we bid on a project for a 6 MGD Wastewater Treatment Plant Expansion and the numbers seemed to be off, so we modeled portions of the project in Tekla Structures and exported them to a spreadsheet. This allowed us to compare the quantities and determine the accuracy of the estimate.Occasionally, an owner will provide us with parameters for a project and ask us to provide a model-based estimate. In this case, we can quickly create a 3D model in Tekla Structures and use the cubic yards of concrete and square feet of forming and finishing to estimate the man hours of those units and determine a budget and schedule. If our bid is accepted, we have confidence that our estimates are correct because we use a constructible, data-rich model to determine accurate quantities. And, we can continue to use that same model once we begin the work.Looking ForwardThe tide is turning. For our business, staying relevant means innovating. We’re still exploring the many ways to incorporate BIM into our work but know for certain that it will continue to play a significant role in meeting fast-paced project delivery cycles and in streamlining our workflow, reducing inefficiencies. and encouraging collaboration across the project lifecycle.

The Southern Illinois University Edwardsville School of Engineering's (SOE) Department of Construction is an award-winning program with a strong reputation for producing successful graduates prepared to shape industry. Luke Snell, P.E., was professor emeritus and founding chair of the department. Once a scholar and educator of the SOE, his recent $15,000 contribution will help continue the department's success. The donation will directly support the SIUE student chapter of the American Concrete Institute.“Concrete is the second most used material in the world … only surpassed by water,” Snell said. “As I developed my research and gained real-world experience as a consultant, using my undergraduate and graduate activities, I seemed to have a knack for solving concrete construction problems. This led me to SIUE to lead the newly created undergraduate construction program. In this role, I could thwart some of those construction problems by reaching students and educating them on good techniques.”

We always hear that the construction industry is resistant to change and innovations that might increase quality and productivity. Why aren’t innovative products and practices more quickly adopted into concrete construction? Or are they? Last week at the Strategic Development Council (SDC) Concrete 2029 meeting we were discussing innovations and where they are or are not adopted. Some examples given of productivity- and quality-boosting innovations were laser screeds, modular formwork systems, and concrete pumps. Innovations that have not taken off were ultra-high performance concrete, self-consolidating concrete, and high-strength steel.So, equipment innovations are adopted but there’s resistance to adopting new materials. Perhaps that’s because the materials typically would have to be specified or permitted by the designer while equipment—means and methods—are the contractor’s option. The contractor doesn’t need permission, designers and owners may not even know what equipment is used and don’t care. Whether or not innovative construction equipment or methods are adopted only depends on the contractor’s decision about whether it will contribute to his bottom line. That seems to point the finger at the codes and specifications as the bottleneck and that is one of the priorities for Concrete 2029 with its emphasis on the Concrete Technical Operating System (CTOS).The definition of this that Concrete 2029 has adopted is “The Concrete Technical Operating System (CTOS) is the technical environment in which concrete structures are designed, built, maintained, renewed, and decommissioned.” A white paper on the CTOS is being prepared by Jim Toscas, formerly executive director or president of several important industry associations, including ACI, PCI, and PCA. He writes that this definition is meant to be “comprehensive, including codes, standards, regulations, conventions, education, training, certification, publications, web-based information resources, computer tools, and technologies used to conduct and support these activities in a manner that provides for life safety, durability, resilience, sustainability, maintainability, and economy.”It’s that last part that is different than where we are today. Rather than just looking at the minimum necessary for life safety, the goal is to incorporate durability, resilience, sustainability, maintainability, and economy into the requirements for concrete structures. Getting the American Concrete Institute to adopt such a standard will be difficult and time-consuming, but that is the goal. Stay tuned.

Concrete dates back to the Roman Empire where it was a widely used building material. At the time, concrete was devised of volcanic ash, or pozzolana and chunks of volcanic rock. 1,400 years later, concrete was rediscovered. In mid 19th-centry France, Ernest Ransome popularized reinforced concrete; his method poured concrete over iron (later steel) bars to improve its tensile strength. In 1903, the first concrete skyscraper was erected, the 16-story building was made possible thanks to Ransome's innovate bar method. Concrete's capabilities also flourished in Ohio, where the first concrete street beat out the widely-used asphalt roads due to its increased durability. Thomas Edison was inspired to design and create cast-in-place concrete homes, which he envisioned would be mass-produced, minimizing construction time and resources. Though Edison's vision never really took off, it did continue to inspire others to push concrete's capabilities. Frank Lloyd Wright's Unity Temple in Oak Park, Illi., considered the world's first modern building, is made of reinforced concrete. Presently, concrete continues to be reinvented.Despite growing environmental concerns, concrete remains the material of choice for most builders, with 3D printing technologies offering it new life: think Shanghai’s 3D printed bridge unveiled earlier this year, the US military’s plans to 3D-print troop barracks, and plans in Eindhoven in the Netherlands to build the world’s first habitable 3D-printed concrete houses.

CEMEX Ventures is accepting applications for the 2019 Construction Startup Competition to identify startups with the ambition to lead the transformation of the construction industry.Under the slogan “Apply. Grow. Make Your Mark.,” the competition challenges entrepreneurs and startups to set their mark in the construction ecosystem, to grow, and to position their solution in the industry. The winners will be evaluated for their relationship with the six areas of opportunity set by CEMEX Ventures: intelligent buildings and cities; optimization of supply chain management; construction with innovative materials and construction methods; and optimization of the productivity, efficiency, and quality of the daily management of work on site, among others.The winning startups will be invited to Monterrey, Mexico, to present their projects to an audience made up of world leaders in innovation, investment, and construction on July 18, 2019. In addition to the introduction to new investors and companies focused on innovation, CEMEX Ventures will work with the startups that best fit its needs."We have a large offering for startups that enter our portfolio, through which we commit to build together a tailor-made path to achieve the best results,” says Gonzalo Galindo, CEO of CEMEX Ventures. "Beyond pure investment, we offer smart money to understand the needs of the entrepreneur and take advantage of our resources to enable them to lead the construction revolution."Ipsum and Prysmex, finalists of the first competition in 2017, are part of the CEMEX investment portfolio and continue an eminent process of expansion to new geographies. Some finalists from the 2018 competition continue to work closely with CEMEX, opening markets in new countries, piloting their technology, and exploring investment possibilities.Launched in 2017, CEMEX Ventures leverages CEMEX’s knowledge of the business with new, leading-edge technologies and platforms, focusing on solving the main challenges in the construction ecosystem through sustainable solutions. CEMEX Ventures has created an open, collaborative platform to lead the construction industry’s revolution, engaging startups, entrepreneurs, universities, and other stakeholders to tackle current challenges in the industry and shape tomorrow’s value ecosystem.

U.S. construction spending dropped 0.6% in December with declines in residential construction and government projects. Even with the decline, construction spending for the 2018 year reached record levels, finishing off with a high of $1.3 trillion. While still a 4.1% increase, this is still a smaller growth percentage compared to increases in spending in previous years.Construction spending had hit a previous record high of $1.16 trillion in 2006, the peak of a housing boom that would begin declining in 2007, helping to trigger a deep recession and five-year retreat in construction spending.Beginning in 2012, construction activity started rising again and in 2016 surpassed the 2006 high. After double-digit gains of 11% in 2014 and 10.7% in 2015, spending increases have slowed in the past three years.

One program in New York City addresses the gender gap head-on, kickstarting recruits' training while gaining a promise from unions to try to reserve 15 percent of on-site apprenticeships for women. The Building and Construction Trades Council of Greater New York is working with a nonprofit group, Nontraditional Employment for Women (NEW), which runs a pre-apprenticeship program for women who want to become plumbers, electricians, carpenters and members of other trades.

AMES, Iowa – The paving crew extended a mixer truck’s chute over the stainless steel electrodes that make up part of a heated pavement technology developed by Iowa State University engineers.And then came the other part: a load of electrically conductive concrete. The first delivery of the thick, heavy mixture slid onto one of the steel rods that send electricity – and ultimately, heat – throughout the concrete.It was a raw, gray October afternoon on the Iowa Department of Transportation campus in Ames. Even the Manatt’s Inc. crew members were in sweatshirts with hoods pulled up.As the crew hustled to work the wet concrete with shovels, spreaders and hand trowels, Iowa State engineers went to work, too.Halil Ceylan – an Iowa State professor of civil, construction and environmental engineering, the director of the Institute for Transportation’s Program for Sustainable Pavement Engineering and Research and leader of the heated-pavement project – recorded video footage from the edge of the work site.Amir Malakooti, a doctoral student and research assistant in civil, construction and environmental engineering and lead construction student for the project, was ready with a shovel. He scooped up the fresh concrete and carefully covered the sensitive temperature probes and strain gauges the researchers were embedding in the pavement.Nearby, doctoral students Sajed Sadati and Wei Shen Theh monitored the paving after helping with last-minute preparations such as pulling yards of cable through protection pipes. Sadati, of civil, construction and environmental engineering, developed computer models for the project that will plug in test data to simulate pavement performance and operating costs. Theh, of electrical and computer engineering, designed the electrical and control systems for the heated slabs, including a new smart control system that can maintain a constant temperature in the concrete.The research team watched as more and more concrete poured from the truck.The Iowa State engineers developed the special concrete containing 1.25 percent carbon fiber by volume. The tiny fibers – just a quarter inch long and about 7 millionths of a meter across – conduct the electricity supplied by the electrodes, but there’s some electrical resistance in the fibers, and that creates heat throughout the pavement.The Iowa Highway Research Board and the Iowa DOT are supporting the three-year demonstration project with a nearly $360,000 grant.Bigger testsThis is the second real-world test of heated-pavement technology developed by Ceylan and his Iowa State research group.In the fall of 2016, with the help of a $2.2 million grant from Federal Aviation Administration’s Center of Excellence Partnership to Enhance General Aviation Safety, Accessibility and Sustainability, the researchers installed two, 15-by-13.5-foot test slabs at the Des Moines International Airport.The small test section next to an airport hangar did, indeed, melt snow and ice – even on the coldest winter days and nights.And so the engineers planned a bigger test just inside a busy entrance to the Iowa DOT campus: 10 heated slabs totaling 75 feet long and 24 feet wide, featuring five different configurations of electrodes – different diameters, shapes and spacing of the stainless steel rods and bars.“The closer the electrodes are to each other, the more energy there is,” Ceylan said. “And larger electrodes are able to pump more energy.”Unlike the airport test slabs, which were out of the way of most airport traffic, the new test slabs will carry traffic and will feature a concrete mix that meets highway specifications.“Big semis go through here,” Ceylan said. “There is a lot of heavy traffic. This will help us learn about pavement performance under heavy truck loads, as well as heating performance and the cost to heat.”Ceylan expects his team to learn a lot about a technology that has already produced four patent applications: “This is a much richer test section than in Des Moines. It’s more complex. We’ll learn a lot more here.”The Iowa DOT wants to learn more about the technology as well, said Bob Younie, director of the department’s Office of Maintenance, and Chris Brakke, a pavement design and pavement management engineer for the department.“This is a chance to see it in place,” Brakke said. “A lot of pavement research is trying something and seeing how it performs.”Brakke is especially interested in seeing how long the new pavement lasts. And, Younie is curious to see if it could be useful for trouble spots on roadways or for sidewalks at the department’s 38 rest areas.“We want people to be safe – whether it’s driving on the road or visiting our rest areas,” Younie said. “And this could be a new tool in the toolbox that we haven’t had before.”Not too complicatedBack when the first load of electrically conductive concrete was poured at the Iowa DOT, a member of the Manatt’s crew pushed a wide levelling float across the width of the test section. It took some leaning – and some flexing of the float’s metal pole – to get the standard concrete tool all the way across the wet concrete.That’s one advantage of this technology, Ceylan said. Those shovels, spreaders, floats and trowels are the same equipment used on any other concrete project. It was the same kind of mixer truck. The same mixing equipment back at the plant. And, except for the addition of carbon fiber, the same concrete used to build highways.“We’re not building a space station here,” Ceylan said. “People can use this technology with regular paving equipment.”The project, however, is a little more complicated than building a typical road. First, a 7-inch base layer of standard highway concrete went down. Then students attached the stainless steel electrodes to the base layer. And, because this is a research project, the students also attached sensors and probes to the base layer. Then 3 inches of the electrically conductive concrete went over the top.This isn’t something road builders would do all the way across a city, a state or a country. But Ceylan said it might be practical for small sections of highway – for example, bridge decks that are prone to icing or steep highway on- and off-ramps.As the research team watched the work crew pour and smooth 21 cubic yards – that’s two truckloads – of electrically conductive concrete, the engineers were confident the project will be as successful as the airport tests. Those airport tests have resulted in several papers and case studies published in materials, construction and production journals."This project is on a much bigger scale and can be used on other highway projects, rest areas or other large-scale applications," said Sunghwan Kim, an Iowa State assistant scientist and the associate director of the Program for Sustainable Pavement Engineering and Research.And so a few months later – after the paving was complete, the controls connected and all the technology tested – steam rose from the hot test slabs during another subzero Iowa morning. Ceylan looked over the ice melting on the concrete and said it was no surprise the new and smarter heated-pavement system was already working very well.

Wytek Construction, custom home builder based in Valrico, Fla., executed the tilt-up construction method on a new home in Clearwater. The technology allows the construction crew to build a shell for the home in as little as six hours, compared to the two weeks it takes during traditional block construction.The walls are made of high-density concrete similar to what's used on roadways and at airports. The material is impervious to water. The traditional block is not. They are also hurricane resistant.

The American Concrete Pumping Association (ACPA) has created a new video called Day in the Life of a Concrete Pump Operator to support the ACPA Workforce Development program.“Our new Day in the Life video will enhance our recruiting efforts by giving viewers a visual representation of real-world pumping experiences,” says ACPA Executive Director Christi Collins. "ACPA members will be able to share the video with pump operator candidates to give them an idea of what operating a pump is really like. It will be a great way to attract potential job seekers who are interested in a concrete pumping career but aren't sure, because they may have no experience with the field."The video, available in both English and Spanish, has an intended audience of ready mix drivers, laborers, those already in construction who may want to change fields, or those who are aware of concrete pumping and are wondering what that career path might be like.The 10-minute video is available on the ACPA YouTube channel at https://youtu.be/9ErMNreMGFE. It follows a pump operator from the time he begins his work day to the time he finishes. The video follows his responsibilities on the job, from clocking in at the start of the day, to getting his paperwork, working with contractors and cleaning out the pump, returning the pump, finishing inspection and clocking out.Day in the Life will be available for members to customize with their own company logo, branding, contact and other company information. The video will be available on ACPA social media sites and will be sharable, with the goal of reaching as many people across the industry as possible.The video is the latest effort by ACPA’s Workforce Development program, which is creating and sharing new initiatives and resources to help ACPA members effectively recruit job candidates. By utilizing the latest technology and strategic partnerships along with creating shareable, informative content, the ACPA is helping increase recruitment in the concrete pumping industry.For more information about the Day in the Life of a Concrete Pump Operator video, contact Taylor White, Workforce Development Coordinator, at 614-431-5618.For more information about the ACPA, visit www.concretepumpers.com.The ACPA is a non-profit association which serves as an advocate for the concrete pumping industry committed to promotion, education and safety for its members and all those coming into contact with a concrete pump on the construction job site. 

A new type of concrete, which could significantly lower the number of deaths during bomb blasts, earthquakes and other disasters, is being developed by an expert from Northumbria University, Newcastle, England. Dr Alan Richardson is working with academic colleagues at universities in India and Canada to create a tougher form of concrete using innovative fiber reinforcement rather than the traditional two dimensional variety.

We all know how a new foreman is found. A foreman leaves and you say to the best worker on the crew (or the one who is bilingual), you’re the new foreman. It doesn’t matter if he or she has the temperament or training to lead a crew, he’s your guy, you trust him, and he’s a hard worker—he’ll get it. And sometimes that works out, or you think it works out, but then you start noticing little things like quality issues leading to rework, or higher turnover of workers on that crew, or the job starts to fall behind schedule. “For field leaders,” says Jeremy Pilgreen with Lemoine Co. at the FMI Field Leader Institute, “it’s kind of like, go jump into the ocean and you’re either going to sink or you’re going to swim.”But there are few things that contribute as much to increased productivity as front-line training (check out this article I wrote for our new web page Building Forward). A recent study by the Construction Industry Institute concludes that the industry is doing a poor job at this. “In general, the Foremen and General Foremen working on today’s industrial construction sites lack the competencies needed to adequately lead and manage their workforce.”Some concrete contractors are getting the message. Mike Schneider, chief people officer at Baker Concrete, notes that they do a lot of safety training and also supervisory skills training. “We’ve put 600 to 700 foremen through this program and it’s helping them develop a proper plan for a safe, quality product.”A goal of Concrete 2029, being developed through the Strategic Development Council, is to improve quality and productivity in construction. One approach is to invest heavily in training by providing a clearinghouse for industry training. There’s a lot out there but many contractors don’t know about it all. Concrete 2029 would develop a central database of training resources.Don’t let your front line guys sink into the ocean!

Follow these instructions for a clean & beautiful driveway. BEFORE USE1. Hose down driveway and allow surface to dry. Also spray all nearby plants, shrubs and grass with water.2. If using a pressure washer, test for surface compatibility in an inconspicuous area with and without the cleaner. Rinse and allow surface to dry before proceeding.USING A PRESSURE WASHER1. Pour full-strength  into your pressure washer detergent tank, or drop your siphon tube into the bottle of Simple Green2. Use low-pressure spray nozzle to apply solution to surface, and allow 5-7 minutes to penetrate soils. Do not allow to dry before rinsing.3. Remove the siphon tube from the container, and rinse at high-pressure setting.4. Use a garden hose to saturate plants, shrubs and grass after cleaning your driveway to rinse away any residue.MANUAL CLEANING1. Mix 2 cups of Simple Green solution to 1 gallon of water in a separate container.2. Scrub driveway in sections using a soft bristle brush.3. Let the solution soak for 5-7 minutes to penetrate soils. Do not allow to dry.4. Rinse with a garden hose, at highest pressure possible.5. Move to a new section and repeat.

Concrete, such as a patio or a basement, can be stained to finish the floor. Once the concrete is stained, it should not be tiled because the thinset will not adhere properly. However, you can work around this problem by using one of two methods. You will need to either restore the concrete so it is close to its original condition or cover the stained concrete with a material such as cement board before tiling over it.Restoring the ConcreteStep 1Clear all of the furniture and accessories off of the concrete floor.Step 2Plug in the disc grinder using an extension cord. Set the grinding wheel on the concrete, and then pull the trigger. Move the disc grinder in a circular motion to remove the layer of stain.Step 3Go over the entire surface of the concrete with the grinder to remove the stain.Step 4Clean the floor with a vacuum, and then begin the process of laying the tile.Attach Cement BoardStep 1Measure the width and length of the concrete floor with a tape measure. Multiply the width by the length to determine the square footage. Use this measurement to determine how many sheets of cement board you will need.Step 2Place a sheet of cement board onto the concrete floor and secure it with the powder fastening gun. Place a .22 shell into the chamber of the fastening gun, and then insert a nail into the barrel.Step 3Set the fastening gun at a 90-degree angle to the cement board, and then pull the trigger. Place a nail every 2 feet along the perimeter of the cement board.Step 4Repeat laying down cement boards and fastening them until you have covered the stained concrete floor.Step 5Begin the process of laying the tile.TipApply the tile, just like any other tiling job with thinset and a trowel, once the flooring has been prepared.WarningEye protection and a face mask should always be worn when grinding concrete.Do not hold the grinder in one place because you can cut a deep gouge into the concrete.Wear ear protection to prevent hearing damage when using the powder fastening gun to fire the nails into the floor.

To clean concrete surfaces safely and effectively, begin with the least toxic cleanser and up the ante as needed. Here's how.By Joe Provey and Bob VilaThe first thing to know about cleaning concrete? You don’t need to be delicate. After all, it’s a very hard material.Basic CleaningThese approaches will enable you to get a long way toward removing ground-in dirt, mildew, spilled paint and most food stains.· Cleaning concrete outdoors: you can rent a pressure washer for use in combination with a biodegradable detergent.· Cleaning concrete indoors: your supplies are likely to be a bucket, scrub brush, and detergent. Hydrogen peroxide or ammonia also work well too.The bad news for the fastidious homeowner is that concrete is a porous material with innumerable tiny voids that can harbor dirt, mold, and all kinds of deep, stubborn stains.You can—and should— try applying common detergents directly to the tough spots and scrubbing with a bristle (not wire) brush. But you may not get far.I once tried cleaning a concrete garage floor that had been exposed to leaky oil pans and transmissions for years and years. Power washing did very little. What helped a little, though ultimately not enough, was scrubbing the area with TSP, then hitting it with the hose.As a last resort, I used an application of muriatic acid—this was the silver bullet that successfully vanquished all the remaining oil spots.Heavy-Duty CleaningHowever, please be advised that you must be extremely cautious with this powerful acid. Don’t even use muriatic acid unless you really need to. If you must use it, be sure to wear protective gear (including protective clothing), and always follow the manufacturer’s directions for dilution.Preventing StainsConcrete sealer is a reliable option for avoiding stains in the first place. Choose a clear silane- or siloxane-based water-repellent sealer  and apply the product with a paint sprayer or roller. Sealing will not affect the appearance or traction of the concrete surface.If the damage has been done and no amount or degree of cleaning seems to be doing the trick, then, if it’s indoor concrete, consider applying a masonry primer and a masonry topcoat. Such a coating would hide the old stains and seal the concrete to prevent further staining.

By KENNETH CRAWFORDOne way to keep your concrete driveway, walkway or walls looking good is to wash them and seal them every 2 to 3 years. Concrete sealer helps prevent water from creeping into the small pores and imperfections that lead to cracks and crumbling. Sealer also helps prevent stains from setting in on the concrete. Sealing concrete after pressure washing is similar to painting walls in your house.Step 1Allow the concrete to dry completely before sealing. If possible, seal in the mid-morning or before the sun is directly over the concrete. This gives you an opportunity to apply the sealer without it drying too quickly. Sealer that dries quickly often leaves behind unsightly streaks or lines.Step 2Open the bucket of sealer, and mix it thoroughly with a wooden paint stick. Screw the handle extension into the handle of the paint roller. Wrap the connection between the paint roller handle and the handle extension with duct tape to help ensure a tight fit.Step 3Slip a medium-nap roller onto the paint roller. A medium-nap roller often rolls better on concrete and evenly distributes the sealer even in the small pores and pockets of imperfections.Step 4Dip a paintbrush into the sealer, and scrape the inside of the container with the bristles to remove excess sealer. Paint corners and edges of the concrete in a thin even layer with the paintbrush. Extend the sealer at least 6 inches from corners. This helps to blend in the sealer with the roller later.Step 5Pour sealer into a standard paint tray. Load the roller with the sealer, using the ribs on the paint tray to remove excess sealer. The roller should be saturated but not dripping with sealer. Roll the sealer onto the concrete in a "W" fashion, just as you would when painting a wall. Be sure to cover the concrete completely, overlapping roller strokes to blend one coat with the next.Step 6Apply the sealer as near as possible to corners with the roller, blending the fresh sealer over the area brushed earlier. Allow the sealer to dry completely, and apply a second coat if necessary.

One of the most satisfying, but time-consuming, outdoor tasks you can take on is power washing your driveway and walkways. While you know that using a power washer can almost magically erase built-up dirt, debris and stains from practically any surface, you might wonder: Can power washing damage concrete?The quick answer is yes, power washing can degrade a concrete surface.You can notice visible damage from water pressure at the level at which even light-duty power washers can operate. Therefore, if you aren’t careful, you can cause irreversible damage to your driveway or patio. Also, some concrete is weaker than others, making some areas more vulnerable to developing lines, pitting or other surface imperfections, not to mention the deterioration to joints if mortar or joint sand is washed away during the process.The top reasons for pressure washing damage are using the wrong nozzle, excessive pressure, spraying too close to a concrete surface and holding the nozzle on a particular spot for too long. As with any piece of equipment you purchase to use on your property, of course, you’ll want to read all instructions thoroughly before you get started.Let’s now go into more detail about how you can give your concrete surfaces an upgrade without inadvertently causing any other problems.How To Pressure Wash ConcreteIf done properly, pressure washing concrete can make a patio, driveway or walkway look as good as new in just a day’s time. For this post, you should know that we don’t make a distinction between power washing vs. pressure washing.If you have decided you’d like to power wash your surfaces yourself, you’ll need to either purchase, rent or borrow a pressure washer. For many homeowners who only power wash once a year, renting a pressure washer makes more sense than finding the space to store a power washer the rest of the year, plus avoiding the hassle of needing to perform any maintenance or make repairs.You’ll probably want to set aside the better part of an afternoon or morning to get the job done, depending on the size of the surface you’d like to work on. Power washing can be very dirty work, so wear shoes that you don’t mind getting ruined and pants to protect your legs from any rocks or loose materials that your pressure washer might send flying. Keep in mind that you may start power washing in one area and decide you need to pressure wash every surface on your property. Yes, it can be that addicting!If you are using a pressure washer for the first time, or if you never got around to it, read through the instructions first. If you’re feeling any bit of hesitation, or if you realize you just don’t have the time or interest in taking this on yourself, call in a professional. Someone who does power washing on a daily basis knows exactly how to clean your surfaces without doing any damage.Now, let’s go over all the steps involved in power washing a surface.CHECK YOUR WATER SUPPLYWithout adequate water supply, your pressure washer will not be able to do its job efficiently. To ensure you have adequate water flow, you can do a quick test by seeing how quickly your hose can fill up a five-gallon bucket. If it takes two minutes or less, you’re good to go.CHECK YOUR NOZZLEIt can be tempting to use a small nozzle, but the wrong size can cause damage to many surfaces. The higher the number, the less narrow and forceful the spray. For most concrete and other masonry jobs, stick to a 25-degree nozzle to spray and rinse your surfaces. You may want to use a finer nozzle to remove grease stains. A 15-degree nozzle should only be used on materials like iron that can withstand even the most intense pressure from your washer. Never use a 0-degree nozzle, because it poses a safety risk.If you’re not sure which nozzle to use, try out the broadest size first and make your way down. Even the 25-degree nozzle is a bit too intense for siding, furniture and more sensitive decks. Only use a smaller nozzle on concrete when you’re applying detergent for a deeper clean.ASSESS THE AREATake a look at the surfaces surrounding the concrete that you want to wash. Sure, the concrete can handle the pressure you’re about to unleash, but what about the windows nearby? The outdoor furniture? The wood deck?Cover any sensitive areas before you start power washing. Also, remove your car if you are going to be power washing around the driveway. If you lose control and the washer blasts your car, you might end up with chipped paint. Also, do a check of any trip hazards that might be nearby. No one wants to trip and lose control of a power washer. Remove toys from the lawn or long cords that might become dangerous when you want to start washing.BACK UPWhen you’re ready to start washing, take a few steps back. Remember, a blast from too close can damage the surfaces that you are trying to clean. Start cleaning by standing at least 10 feet away from the area that you are trying to hit with water. Once the pressure washer starts running, feel free to step a little closer until you are comfortable with the distance from your surface.AIM HIGH AND KEEP IT MOVINGOnce you are ready to wash, aim for an angle higher than where you want to hit. Turn on the washer on to spray at 3,000 psi and adjust your stance accordingly. Using any more pressure can be risky, especially if your concrete is not in good condition. As you wash, keep the nozzle moving in one direction. This will prevent etchings and other damage to the surface where you are washing. We recommend that when you’re cleaning your concrete with detergent, you move from the bottom of your surface and go up. When you’re rinsing, start from the top and make your way down.If you have never power washed before, you should know that there is a learning curve and that you can’t really rush the process. You’ll probably want to start on an area that’s less visible until you get the hang of how your pressure washer works. You’ll need to stay a consistent distance from your surface for uniform results. If you start pressure washing further away, and then get closer, some parts of your driveway will look darker than others. You may want to focus on one area at a time. Power washing can become tiring, so you’ll probably need to take breaks, especially if you are working on a large area.While you are going to do everything in your power to be cautious when using your pressure washer, things can still go wrong. What can go wrong when pressure washing?Damage From Power WashingWhile concrete is among the strongest building materials available, it is not immune to wear and tear. Cracks, spalling and imperfections can develop over time, particularly on driveways that get a lot of foot and car traffic. A pressure washer delivers water 30 to 80 times stronger than your garden hose.You know you’ve damaged your concrete due to a bad power washing job if it looks etched, creating an uneven surface and an unappealing driveway or surface. However, etching and other types of damage to concrete is not always due to extreme pressure, and could have existed before you removed the layer of dirt and grime that was on top of a surface.If you recently installed concrete, you should hold off on power washing temporarily. Concrete needs at least a year to bond in a way that can handle this type of pressure. If you need to clean concrete without using so much pressure, you can try mixing water with dishwashing detergent and scrubbing off the stain or discoloration yourself.Another type of concrete damage we come across is when homeowners power wash their concrete too frequently. Concrete should be power washed annually, so if you power wash your concrete once a month (or even more frequently), it’s more likely to wear down and be subject to damage.Keep in mind that if you switch from power washing your concrete to another type of surface, such as your outdoor furniture, you’ll probably want to decrease the amount of pressure. Wooden decks can benefit from pressure washing, but some can get clean with the use of a garden hose. Power washing your roof is generally a bad idea, since you can be thrown off balance if you turn on the machine while you are on a ladder. Shingles can also be dislodged by a pressure washer. It’s generally also a bad idea to pressure wash your car, since your paint can be damaged in the process. Even contact on your skin from a high-pressure spray can cause lacerations and bruises, and eye injuries can send you to the hospital.There are also some homeowners who don’t necessarily have etching on their concrete, but there are marks from power washing—so, what can you do about those?How To Remove Power Washer MarksIf you do find yourself leaving marks on your concrete, don’t fret. Leftover marks are a lot easier to deal with than etches or actual damage.Take a look at the concrete surface that you have just power washed. You might see some leftover debris or pieces that didn’t make it off the surface. If you feel confident in your power washing abilities, you can go back over the concrete with a much broader nozzle. Or you can simply brush it off or use a gentle spray to remove the debris. Usually, these marks come from rushing through the job. If you start seeing marks while you are pressure washing, slow down a bit and make sure to go over each section thoroughly before moving onto the next area.While most homeowners just deliver water in a high-pressure spray to remove marks on a surface, you can also try using a detergent to remove marks or discoloration. If you go this route, you should use a smaller nozzle when applying detergent. The detergent you purchase should have more detailed instructions on how to apply the product. If you follow those directions, you should get the best results with minimal power washer marks.Sometimes marks are not from the power washer itself but from oil, grease or more stubborn build-up. In those cases, you can experiment with a different nozzle or get a bit closer to see if a higher degree of pressure removes the marks. If the power washer marks make you nervous about picking up the nozzle again, it’s time to call in a professional.Additional Power Washing TipsWhat else should you keep in mind before you start pressure washing your concrete?DO YOUR HOMEWORKRegardless of the size of your job or how long you think you will be using the power washer, you should take precautions. All that power can make a lot of noise, so before you rent or buy a power washer, do some research. Some models make more noise than others, which may be a consideration if you don’t want to bother your neighbors.In addition to wearing proper clothing, safety experts recommend protecting your ears with earmuffs or headphones, even if you’re using a safer or smaller model. In addition, wearing gloves, goggles and long-sleeved clothing can prevent any exposed skin from feeling the pressure. Try to sweep the area you want to power wash so you don’t risk having rocks or other debris hit you or someone nearby. Never point the nozzle at a person so that you can avoid any possible injuries.BE CAUTIOUS ABOUT THE ENVIRONMENTPower washing may be prohibited if your area is going through a drought. Even without these restrictions, it’s important to consider the environment and wasting water. If you follow our tips on properly power washing your home or property, you shouldn’t have to waste water, but be mindful with how much you are using.Power washing can be more than just water.Take a look at the ingredients in any cleaning products you use with your power washer. Are they environmentally-friendly? Could they cause damage if they end up on your lawn or in the sewers? Here are some ingredients you may want to avoid:· Hydrofluoric acid· Muriatic acid· Sodium hydroxide· Bleach

Is a decorative concrete floor right for you? Here, we separate the truth from the reality to help you make an informed decision.By: Anne Balogh, The Concrete NetworkWhen people are first introduced to the beauty of decorative concrete flooring, they are initially “floored” by its good looks (sorry, the pun was too tempting to pass up). However, once that love-at-first-sight reaction fades, it’s often followed by skepticism about the practicality of concrete flooring, especially in a home environment. Many homeowners will ask: Beyond its aesthetic attributes, is concrete really a flooring material I can live with for the long term?Like any flooring material, concrete does have some inherent drawbacks. However, many of them are easy to overcome, and in the end, the positives of concrete flooring far outweigh the negatives. To help you evaluate whether concrete floors are a good fit for your lifestyle and aesthetic tastes, here are frank answers to some common questions about concrete floors.Are Concrete Floors Cold and Damp?The truth:Yes, concrete can be cold, but no more so than ceramic tile or natural stone flooring. And yes, concrete floors can transmit moisture vapor if they aren’t insulated properly or if the slab is built on a poorly drained sub-base.The reality:Concrete doesn’t have to be cold. Its thermal properties give it the ability to store and radiate heat. By embedding radiant heating cables in concrete floors, for example, you can keep floors toasty warm in the winter and you can control the temperature level.In properly constructed newer homes, today’s building codes typically require installation of a vapor barrier under concrete slabs to block moisture migration and that feeling of dampness.If the home is built to take advantage of solar radiation entering through windows, concrete floors will absorb the heat from the sun to keep rooms warmer in the winter.In summer and in hot climates, a cooler floor can be an advantage and can actually help lower air-conditioning costs.Are Concrete Floors Loud and Hard on the Feet?The truth: Yes, concrete is a hard material and won’t cushion or “give” under bare feet. And concrete floors can be loud and produce an echo effect, but no more so than ceramic tile, natural stone flooring, and some hardwood or bamboo floors.The reality:Concrete’s hardness also contributes to its durability and abrasion resistance. In a commercial or warehouse setting, hard is good. You need a hard surface that can stand up to forklift traffic and heavy foot traffic.For a residential floor, you can help cushion concrete with area rugs, which are easier to clean than wall-to-wall carpet.While concrete may be hard, it’s not abrasive to the feet, especially if it’s polished or has a smooth finish.You can muffle the echo effect by using sound-absorptive materials in the room, such as area rugs, curtains, pillows and wall fabrics.Are Decorative Concrete Floors Expensive?The truth:The initial outlay for decorative concrete may exceed the cost of a low- to mid-priced floor covering, such as carpeting, vinyl tile and wood laminates.The reality:When compared with high-end floor coverings, such as ceramic tile, slate and marble, decorative concrete is often an economical alternative. Plus, skilled concrete artisans can duplicate the look of these pricier materials.The life expectancy of a concrete floor will far surpass that of most floor covering materials. That means in the long run you can save money because you’ll never need to rip out and replace worn or damaged flooring.Is Decorative Concrete Maintenance Free?The truth: No type of flooring material is truly “maintenance free,” no matter what the manufacturer may claim. While concrete floors are relatively easy to maintain, compared with other types of floor surfaces, they aren’t completely maintenance free. How much maintenance your floor will need largely depends on the amount of traffic it receives. The maintenance needs of a residential floor will be much different than those for a floor in a high-traffic commercial or retail environment.The reality:In most cases, residential concrete floors experience light foot traffic, and a simple cleaning regimen of occasional sweeping and damp mopping will keep concrete floors looking like new for many years.When protected with a good sealer and a coat of floor finish or wax, concrete floors are highly resistant to staining, chemicals and abrasion.If your concrete floor ever loses its luster or shine, cleaning of the floor and reapplying a coat or two of floor finish will normally bring it back to its original state. In a non-aggressive environment such as a home, it’s not uncommon to have a year or more go by with just light maintenance before it’s necessary to buff and refinish the floor.In areas of heavy traffic, such as entrances and foyers, you can reduce maintenance and wear and tear by using floor mats, both inside and outside of the entryways.Are Concrete Floors Slippery?The truth:They can be, especially when wet, but no more so than vinyl, linoleum, marble or ceramic tile floors.The reality:Application of a high-gloss sealer to protect and enhance decorative concrete may reduce traction somewhat, but that’s easily remedied by mixing a nonslip additive into the stain or sealer before application.Kept clean and dry, polished concrete floors are generally no slicker than plain concrete surfaces. And they tend to be less slippery than waxed linoleum or polished.How Long Does Concrete Flooring Last?Yes, many flooring options are initially cheaper than decorative concrete. But concrete will last longer and eventually give you a better return on your investment. When you amortize the cost of a concrete floor over a lifetime, the price can be comparable or even lower than other high-end flooring materials. Concrete floors rarely if ever need replacement, especially if properly installed and maintained.Top Misconceptions about Concrete FloorsIn a recent survey about concrete floors that we presented to recipients of our “Concrete Quest” newsletter, we gathered some revealing insights into what consumers like and don’t like about concrete floors. While most people love the look of decorative concrete floors and their ability to be customized, they had a few grievances as well, particularly the four concerns listed below, based on the percent of responses.Some of these criticisms are valid, but they can also apply to other types of hard flooring surfaces. And in defense of concrete, we’d like to point out why a few common objections about concrete as a flooring material are more misperception than fact.They can crack (48%)The most common objection to concrete floors (48% of respondents) is the potential for cracking. However, some people actually love the rustic, organic look that can be achieved by staining the floor and leaving minor random cracks exposed. While these can be perceived as an eyesore, micro-toppings offer the ability to hide them under a smooth, new surface that can accept a wide array of decorative treatments, including staining, stamping, and stenciling.They can be slippery (25%)Any smooth flooring surface, including vinyl, linoleum, marble and ceramic tile, can be slippery, especially when wet. With concrete, you can easily remedy the problem by mixing an invisible nonslip additive into the stain or sealer before applying it to the floor to give the surface more traction.They are too cold and hard (20%)Concrete can be cold, but no more so than ceramic tile or natural stone flooring. The advantage of concrete is its inherent ability to store and radiate heat. By embedding radiant heating cables in concrete floors, for example, you can keep floors warm in the winter and, better yet, control the temperature level. If your home is built to take advantage of solar radiation entering through windows, concrete floors will absorb the heat from the sun to keep rooms warmer in the winter.No doubt, concrete is hard under bare feet. But that hardness also contributes to its durability and abrasion resistance. For a residential floor, you can help cushion concrete with area rugs, which are easier to clean than wall-to-wall carpet.They look too industrial (7%)Certainly plain, unadulterated gray concrete can be perceived as sterile and “industrial.” However, anyone who has seen a concrete floor enriched by a brown or earth-toned stain knows that concrete can be made to look warm and inviting. In fact, brown is the most popular color choice for concrete floors, based on our survey.Author Anne Balogh, ConcreteNetwork.com Columnist and Senior Editor of Concrete Network Magazine 

by Concrete Sealer ReviewsWhy has my Brick Paver or Stamped Concrete Sealer Turned White?This is a very common question and a fairly common occurrence. Typically this happens to filming acrylic-based sealers that leave a shine on the surface. These sealers are typically applied to brick pavers and stamped concrete surfaces to enhance the overall appearance.There is no one specific reason that your old sealer has blushed by turning white or cloudy so there is no one remedy to fix. In this article, we will go over the main reasons that your sealer has failed so you will be able to fix this problem permanently.Cheap Acrylic SealerIn general, just stay away from the paint stores or Big Box stores brands. These “wet look” sealers have a high failure rate due to the inferior acrylics used.Solution: To fix you will need to remove the sealer with a concrete or paver sealer stripper.Trapped Water/Moisture and Over Applied SealerTrapped moisture under the sealer is the most common reason that the sealer has turned white. This happens to sealers that are not breathable or over applied. The sun will raise the moisture out of the concrete or bricks but the water cannot escape as it is trapped under the sealer.Solution: Applying a solvent such as Xylene or Lacquer Thinner will emulsify the current sealer, removing the trapped moisture and restoring the shine. Not a guaranteed fix but is worth the attempt.Solution 2: If the solvent does not work you will need to use a sealer stripper to remove and start over.Efflorescence Salts Trapped under SealerEfflorescence is a soluble salt that raises to the surface of the concrete after it is installed. This may never form or may take up to a year to show. Make sure that all efflorescence is removed prior to sealing the surface.Solution: Strip off the sealer first then use an efflorescence cleaner to remove the white residue.Polymeric Sand Issue (New as of last few years)We have seen more and more issues with polymeric sand installs. Not so much an issue with the sand, but with poor installation. Polymeric sands are installed by sweeping the sand into the joints then blowing off the excess from the top of the surface. The sand is then misted with water to activate the polymer bond. The problem arises when the sand is not completely removed from the top of the surface prior to misting with water. The polymeric sand in many cases contains “cementitious” properties. This, when activated by water, may leave a thin layer on top called a “poly haze”.Solution: Strip off any sealer then use a mild acid or white vinegar to remove the poly haze.

You can brighten up a dull gray concrete surface with a bright coat of paint. All it takes is time—and some very careful preparation.By Bob VilaTo paint concrete successfully—so that it looks good and lasts a long time—proper preparation is of paramount importance. If you follow the steps below, you can achieve satisfying results no matter what concrete you choose to paint, basement floor or wall, outdoor patio, or any other part of your property.PROJECT SUMMARY00001. Use patching compound to fill any holes, scratches, or gouges in the concrete surface.00002. Clean the concrete thoroughly with trisodium phosphate (TSP) and warm water, then let dry.00003. Apply paving paint or porch-and-floor enamel, first to the perimeter and then the middle. Let dry.00004. Scrape away any lumps or bump, and sand any areas where the paint failed to adhere.00005. Apply the second and final coat of paint, then let dry.MATERIALS AND TOOLS – Concrete filler– Power sander with finegrit disks– Pole sander– Trisodium phosphate or other alkaline cleaner– Metalbristled brush– Paving paint (or porchandfloor enamel)– Paintbrush or roller– Putty knife– Protective gear (rubber gloves, dust mask, glasses) STEP 1: Patch gouged or otherwise damaged areas with concrete filler.When you set out to paint concrete, the process begins rather unglamorously with concrete filler, which acts as a primer for the painted surface. Use the patch compound to fill in all holes, scratches, and gouges in the concrete. After allowing sufficient dry time, sand the repaired areas until they are smooth.STEP 2: Clean the concrete surface with TSP.Using a solution of trisodium phosphate (TSP) and warm water, clean the concrete floor or surface thoroughly, removing all the oil and grease that would otherwise discolor the paint job. Work the solution into the concrete with a metal-bristled brush. To determine the proper ratio of TSP to water, read the package instructions, but figure on about one-quarter cup TSP to one gallon of warm water. TSP can harm skin and eyes if it makes contact, so be sure to wear full protective gear.STEP 3: Let the surface dry thoroughly before you begin to paint the concrete.As the TSP reacts with the concrete, you are likely to notice a slight bubbling across the floor or surface. Let that bubbling continue coating the concrete for about 20 minutes, then hose it off, completely washing away the TSP. Let the surface dry for two days before painting. After it dries, run your hand over the concrete; it should feel like 120-grit sandpaper.STEP 4: Brush paint onto the perimeter of the concrete.Sweep the area or wipe it down with a dry cloth, depending on the orientation of the surface. Now you’re ready to start painting. Use a paintbrush to apply an initial coat of paving paint (or porch-and-floor enamel) over the perimeter of the area. A regular medium-size paintbrush enables you to achieve good coverage when painting corners and edges, whether you’re working with an interior or exterior space.STEP 5: Roll on more paint to cover the interior.Next, use a paint roller to fill in the sections that you didn’t coat with the brush. If you’re painting a concrete floor, remember to start on the far side of the room, so you end up finishing near a doorway or another convenient stepping-off point. In other words, don’t paint yourself into a corner of the floor! Let that first coat of paint dry for at least 16 hours or so.STEP 6: Scrape or sand surface imperfections.Putty knife in hand, scrape away any protruding lumps or bumps that appeared after the first coat dried. Sand any areas where the paint failed to adhere; if you do end up sanding again, don’t forget to sweep again, too.STEP 7: Apply a second and final coat of paint to the concrete.Apply the second coat of paint in the same way that you applied the first. This time around, however, press down firmly with the roller, mashing the paint into the holes the first coat didn’t penetrate. Before considering the project complete, let the second coat dry for about five days, particularly if the painted surface is a heavily trafficked floor.

When people think of epoxy coatings, residential garages and auto showrooms come to mind. Epoxy coatings, however, are ideal for numerous applications including healthcare institutions, industrial settings, offices, and much more.  Decorative epoxy coatings come in an amazing variety of colors and styles, including solid color, metallic, quartz, and flake. Because of the endless design capabilities, no two floors are really ever the same.  Epoxies are durable, tough, and resistant to oil, grease, and most chemicals. They are also resistant to impact and extreme wear, making them ideal for locations with a lot of foot or vehicle traffic. Some epoxy coatings even provide added floor protection in environments subject to varying temperature extremes, such as commercial kitchens, refrigeration units, or deep-freeze coolers. Epoxy coatings can also be designed with various surface textures and system build thicknesses. This provides multiple levels of slip resistance, making the environment safer and reducing the potential of slip-and-fall accidents.This is an attractive benefit for businesses concerned with employee and customer safety.   Concrete must be properly prepared before a coating can be applied. Epoxy coatings are also referred to as “epoxy paint.” And like any other paint job, proper preparation of the surface is essential.  Preparing a concrete floor (removing oil spots, cleaning/degreasing the floor, scrubbing, vacuuming, etc.) can be quite labor intensive. Applying the epoxy coating properly so as to avoid blistering, puckering, flaking, or other application errors is best done by a fully trained, professional concrete flooring contractor.  Before an epoxy coating is applied to the floor, Jon-Don highly recommends considering the following:· New slabs of concrete should be allowed to fully cure for 30-60 days before a coating is applied· If a sealer was previously used on the concrete (if water beads up on the surface), do not use epoxy. The sealer should be removed first by shot blasting.· Previous coatings or paints should be removed before a new epoxy coating is applied.· Any cracks or concrete spall should be filled and stabilized before a new epoxy coating is applied.· Determine if moisture or dampness is coming up through the concrete from the ground. If moisture is evident, your floor isn’t suitable for epoxy. If relative humidity is greater than 75, a moisture migration system should be used. Training Opportunity: Concrete flooring professionals who are new to the industry, or old pros looking to brush up on the latest techniques, would benefit from attending the Epoxy Flooring Skills Level 1 and Level 2 training courses. From start to finish, technicians will learn how to apply epoxy coatings step by step, and even how to perform simple crack repairs.

Concrete is a popular building material because it is inexpensive and durable. Plain gray exterior concrete -- whether in poured-in-place, precast, or block form -- tends to be a little boring to look at, but did you know you could paint it?You'll need some special supplies and techniques to cover concrete's rough texture and to help it hold up in any weather. The brilliant results are worth it, though. Just think of the cute and colorful cottages so popular in Florida -- they're made of hurricane-resistant concrete painted in all kinds of fabulous pastel hues and they look great. Here's a step-by-step guide to painting outdoor concrete walls, floors, and driveways.1. Allow yourself plenty of time to get the job done right. This is not a quick, one-Sunday-afternoon project. You will need to wait at various stages along the way, while the concrete dries, or the primer or paint cures.2. Clear the space. The paint is going to have to cure for as long as a week after you apply it, so that means you'll have to find an alternate parking spot for your car if you paint your driveway ... or store outdoor furniture when it's your patio that's about to be refurbished, to name two examples.3. Clean up. Scrape off moss and pull weeds that may be growing on or near the concrete. Use a pre-paint cleaner to get rid of dirt and grease so they won't cause the paint to discolor. Strip off any old, peeling or flaking paint with a scraper, wire brush, and sandpaper. Then finish up with a pressure wash. Make sure the concrete is completely dry before you begin to paint.4. Repair any holes. Fill in all deep cracks, holes, or uneven areas in the concrete with concrete patch or mortar, applied with a trowel and allowed to dry as per the manufacturer's directions.5. Seal the concrete against moisture, when painting a previously unsealed house wall or other surface.6. Prime your concrete surface to fill in its pores and help paint adhere. Apply exterior grade concrete block filler, which will require 2 hours' drying time and another 6 hours before it can be painted.7. Don't use regular exterior paint -- it's not made for concrete and will tend to crack and peel as the material expands and contracts. Instead, choose dedicated driveway or masonry paint (aka "elastomeric"), which may be tinted to a color you choose. Because this is much thicker than standard exterior paint, you'll need special equipment. Look for masonry paintbrushes and "texture" or "high capacity" rollers. Attach a long arm to your roller or an extender to your brush to make it easier to cover large areas.8. Add masonry paint thinner to the paint for your first coat and mix well. Apply paint smoothly and evenly. You are likely to need two or more coats for proper coverage. Let dry for at least several hours (check instructions on the paint can) before applying an additional coat. The second and any subsequent coats do not require thinning.9. Apply concrete sealant to protect the paint and make your handiwork last longer, after the final coat is thoroughly dry. Purchase sealant in your choice of glossy or matte finish, and apply with a brush or roller. A second coat may be advisable in areas with heavy vehicle or foot traffic or where furniture is frequently moved across the floor, such as a driveway, swimming pool surround, or patio.10. Allow the paint to cure for three to four days for an exterior floor, or a full week for a concrete driveway, before you start to use the good-looking new surface.

If you own a home or a building, it is almost a certainty that you have used concrete in the construction. Concrete is the most common man-made material on Earth, as well as being one of the strongest. Without concrete, there would be no foundations for buildings, no bridges, no sidewalks, to name just a few of the inconveniences. However, we often do not take the appropriate steps and measures to protect our concrete investments for the long term.While concrete is strong and durable, it is a fallacy to believe that it needs no protection. In fact, without proper protection, concrete will not even be that strong or that durable. Just look at cracked sidewalks, crumbling bridges, and leaky foundations if you need further proof.  Concrete can degrade due to the elements, wear, or really any number of reasons. While it has the potential to last for tens of thousands of years (theoretically), it can degrade over the course of a decade if the proper care isn’t taken.The most cost effective way to protect concrete is to use a concrete sealer as soon as the concrete has finished curing. Without a concrete sealer, the concrete will be vulnerable to damage that could cost incredible amounts of money to repair – as many home and building owners have found out the hard way, it is a lot cheaper and easier to just prevent the damage by using a concrete sealer. Even if you move into a home or acquire a building that has not ever been sealed, it is not too late.Concrete sealers come in a variety of types. Topical sealers like acrylics are excellent choices for decorative concrete to enhance the color, add a high gloss shine, or matte finish while protecting from sun, rain, mold and mildew. There are other surface sealers, like epoxies, urethanes, and polyaspartics, that should be used for high traffic/high chemical risk concrete surfaces that are found in places like industrial warehouses, retail stores, and even airports. There are penetrating sealers, like silicates that chemically react to densify and increase the concrete’s strength and penetrating waterproofers that create a hydrophobic barrier to prevent moisture and vapor transmission.

BY JUAN RODRIGUEZEpoxy floor coatings are commonly used for commercial and industrial flooring. Epoxy coatings are normally applied over concrete floors to provide a high-performance, smooth, and durable surface that can last many years and withstand heavy loads. Many industrial sites, warehouses, and commercial buildings rely on epoxy floors to maintain clean and safe conditions for workers, equipment, and inventory.Epoxy Floor Coating PreparationAn epoxy coating requires a clean and slightly porous surface to adhere properly. Epoxy may not bond to sealed or polished concrete. The concrete also must be fully cured. Before apply epoxy floor coating, it is important to patch and repair all major cracks and chips in the concrete surface and to remove all grease. If the concrete is old, test the surface for previous layers of epoxy or other products that might have been applied over the years. To test for sealant, pour a small amount of water onto the floor. It should soak in. If the water beads on the surface rather than soaking in, it likely has been sealed and may not be suitable for an epoxy coating.Before applying an epoxy coating, make sure that the temperature is suitable, and follow all manufacturer's recommendations. Unfavorable temperatures can cause the epoxy to bubble and peel. Epoxy is a two-part liquid that you mix before application. Once the product is mixed, you have a limited time to apply the epoxy coating before it starts to harden.Epoxy Primer FormulasDepending on the product being applied, you might need to apply an epoxy primer and finisher coat. The primer is applied just like paint and is allowed to settle for several hours before the epoxy goes on. To apply the primer, cover the floor with a thin layer of water, then spread the primer with a roller pin on a pole, spreading it out in a thin layer over the entire floor. Let the primer dry, then apply a second coat. The finisher is applied in the same manner as the primer but without the water layer.Epoxy Floor Coating AdvantagesEpoxy floor coatings offer many advantages when compared to other traditional coatings applied over concrete:· Creates a shiny high-gloss surface that can significantly increase the brightness of interior areas· Offers a hard-wearing durable surface able to withstand heavy and continuous traffic· Quick and easy to install, requiring no layout, cutting additional adhesives, or special tools or equipment· Durable and easy to clean· Ideal for warehouses and industrial applications· Resists oil stains and water· Creates a seamless surface that can last many years· Can be combined with paints and colors to mask off chips and cracks· Provides a chemically resistant surface ideal for manufacturing plants· Offers enhanced safety when the surface contains anti-slip additives· Can be applied in different patterns to create visible driveways and/or identify walkable areas· Prevents wear and tear on existing concrete floors· May be compatible with self-leveling products that can be applied over new or old concrete, depending on the product· Requires little or no major maintenance

A fresh coat of color solves everything! And it's easy when you can rely on strong, innovative tools that take the heavy lifting out of painting even a large floor.By Glenda Taylor and Bob VilaConcrete is one of the most durable construction materials around, but the characteristic dull gray of a concrete slab can seem cold and unappealing, especially as flooring. Lucky for many DIY-inclined homeowners, concrete is also a fairly versatile material that offers many options for repairs, alterations, and improvements. You can scrape off dried-on gunk, fill cracks, change the color—and even add patterns!The bottom line: If you have concrete floors in your basement, garage, or screened-in patio, you don’t have to live with lackluster. You can refresh the entire space by painting your concrete floors.In combination with the right tools and techniques, today’s masonry paints, designed specifically for concrete, make it easy to turn a drab concrete floor into an attractive surface that can complement a variety of spaces, both indoors and out.STEP 1: Prep the SurfaceEven after your concrete floors have been covered with a new color, their condition will remain visible. Lumps, cracks, and other imperfections that you didn’t deal with before you painted will retain just enough texture that their shadows will attract attention. That’s why you want the surface to be as smooth and clean as possible before you begin painting concrete floors.Get rid of the gunk.Garage and basement floors are notorious for stuck-on paint splatters and adhesive residue. Fortunately, scraping away accumulated gunk doesn’t have to be a back-breaking task if you use a scraper that attaches to an extension pole, such as Hyde Tools’ 3” Bent Chisel Scraper (available at hydestore.com; $11.84). This heavy-duty hand tool features a rock-hard, high-carbon steel blade that makes quick work of scraping away hardened residue. Thread a standard extension pole into its red handle, and you’ll find that the blade is bent at just the right angle for you to scrape standing comfortably.New paint sticks only to a clean, dry surface.For best results in the long run, with minimal peeling, start with a concrete degreasing product that’s suitable for your floors (depending on whether they’re interior or exterior surfaces). Because concrete degreasing products are often applied to damp concrete, suit up in protective eyewear, clothing, and gloves, and spray down the floor.STEP 2: Prime and PaintPriming before you paint concrete floors helps ensure that your new look will stick. Select a primer that’s compatible with both concrete and the epoxy paint that you’ll use as a finish coat. (Epoxy paint is the best choice for floors, which take a lot of abuse. You’ll get the most durable results from epoxy, and it will hold up better over time than latex paint.) Be sure that both the primer and paint are suitable for the location of your floor, whether it’s an interior or exterior surface.Wait until your concrete floors are dry before you prime.Moisture will prevent the primer and paint from adhering properly. An easy way to tell whether the floor is dry enough is to place a small piece of kitchen plastic wrap (about 12” square) to the surface of the concrete floor. Seal all edges with tape. Wait overnight and then check the plastic. If moisture has condensed on the underside of the plastic, let the concrete dry another 24 hours and test again. When no condensation is present, you’re good to go.STEP 3: Seal the DealOnce the epoxy coat dries (check the label for drying time), your floor will look amazing, but for the longest-lasting results, it’s a good idea to apply a sealant. Choose a sealant for exterior or interior use (depending on the location of your floor) and one that’s compatible with the epoxy paint you applied.

By LAURIE BRENNERNot all home improvement experts agree on what is better, concrete paint or concrete stain, because it depends on your desired results. Concrete stain embeds the surface to color it translucently, while opaque concrete paint covers the top of the concrete but is subject to chipping and peeling when improperly applied. Concrete stains go on quicker, dry faster and take less work than concrete paint, but they offer no significant protection. A paint designed for masonry -- an elastomeric paint -- covers and protects the concrete's surface and keeps it from drawing in moisture, and it won't chip or peel if the concrete surface is properly prepared. In the end, the option that works best depends on where you want to use the product.Concrete StainsWith two basic types of concrete stains, the easiest option is the water-based stain that goes on quickly after you clean the concrete. It usually requires a sealant after application to prevent fading. Acid-based stains react to the concrete's ingredients, offer fewer color options than water-based stains and are a bit more complicated to use. Water-based stains can require more than one application of the stain if you want to deepen the color. Concrete stains give you a decor option for coloring concrete floors, but they don't actually protect the concrete. Acid-based stains can be dangerous when applying, and can cause severe skin, eye and lung irritation. The use of face masks, heavy gloves and protective gear are needed.Concrete PaintConcrete paints completely cover and protect the concrete surface, but require a lot of prep work. Before you can apply a concrete paint, clean it with degreasers to get rid of any oil or grease stains, followed by muriatic acid to remove any curing chemicals on the concrete's surface. (Muriatic acid is extremely dangerous if inhaled, and prolonged exposure can cause circulatory failure. Use caution and read all instructions before working with muriatic acid.) Seal the concrete with a primer-sealer product to prevent it from moisture retention before applying a concrete paint. Concrete paint works for both indoor and outdoor application, as does a concrete stain.Epoxy PaintsManufacturers have created two-part epoxy concrete floor covering products that don't require you to seal or prime the concrete ahead of time -- as long as it is clean. Many people choose this option for garage floors. The epoxy coating leaves a shiny surface sometimes impregnated with bits of colors or aggregates for a decorative touch. These sealed surfaces can last for a long time when cared for properly. Like the other options, epoxy is hazardous when applying, and the area should be well-ventilated when working.Pros and ConsConcrete stains work well on interior or exterior surfaces to add color to the concrete; when sealed and polished they create a high sheen floor, an easier solution to use for interior decorative floors or outdoor patios. Because stains are translucent, they won't hide any of the concrete's flaws. Concrete paints also provide a decorative touch, but are better suited to applications where the concrete also needs sealing and protection -- inside a garage or basement, for example, or where you want to hide damaged or stained surfaces. Epoxy paint is used similar to resins, in that you add a catalyst to activate it. These products work best in areas with heavy use, such as garage or workshop floors. The drawback to these paints is that you must apply all the paint once you add the catalyst, because once it hardens, it's unusable. All products have safety concerns that should be considered, since some of the chemicals and acids used can be extremely dangerous to apply.Colored ConcreteYou can also add stains to concrete when adding new concrete for a patio. This type of stain impregnates the concrete through and through, and becomes part of it. Masons often include a pigment in concrete when they stamp it to make it look like brick, paving stones or natural stone driveways, walkways and sidewalks.

TYLER LACOMAConcrete overlays are finishes that cover up concrete slabs. People install these overlays for different reasons--sometimes they are necessary, as a repair step in fixing a badly flawed concrete floor. At other times, the overlays are made from epoxies and owners use them for decoration, painting them so they mimic other types of surfaces. While concrete overlays can have many purposes, owners must always install and care for them properly, or they can develop problems.AdherenceNo matter the overlay, the layer must bond with the concrete beneath it. For many mortar layers, owners must first lay down a concrete adhesive to cement the two together--without this adhesive, the top layer can develop cracks and other structure problems. With more liquid-based overlays, owners must thoroughly clean the concrete of all dirt and oil, or the surface will not adhere properly.MoistureMoisture is a common problem for concrete floors. When moisture enters the floor, it seeps easily through the concrete's porous material and causes mold and rot problems below the floor while creating structural issues throughout the concrete. When installing any type of overlay, owners must use sealants to protect it from moisture.DurabilityConcrete overlays are thin and do not last as long as the slabs beneath them. Some overlays show durability problems within several years. Acid etching and other types of concrete color work tend to fade away over time unless the floor is consistently sealed. Owners must pay close attention to maintenance and cleaning with their concrete overlays if they want them to last.DesignsConcrete designs are imprinted and painted on epoxy layers. While this can give a concrete floor an entirely new appearance, it also requires considerable skill to make realistic stone or tile shapes, colors and designs. Owners cannot usually create these complex effects themselves, and must hire a professional for advanced work.

Written by Jeff BenekeIf you have a concrete garage floor, driveway, sidewalk, or patio that is starting to show its age, you are left with two options: You can demolish and remove the old surface, prepare the base, and pour a new slab; or you can use a resurfacing process to restore the slab to its youthful appearance.Sometimes a concrete slab is just too unstable or too badly damaged to make resurfacing possible. But when the problem is just superficial cracking, discoloring, or minor chipping or spalling, resurfacing is a very good option. It's a project that just about anyone can tackle, and it's a lot more affordable than replacing the concrete slab.What Is Concrete Resurfacer?There are lots of concrete mix products on the market—including mortars, repair patchers, fast-setting concrete mixes—and it can be hard to choose among them. Concrete resurfacer is a special cementitious product that blends ordinary Portland cement, fine sands, polymer modifiers, and other additives aimed at providing adhesion. Unlike other cement products, it is designed to be applied in very thin coats (no more than 1/2 inch thick), and its additives provide good adhesion to an existing slab.If you have a concrete garage floor, driveway, sidewalk, or patio that is starting to show its age, you are left with two options: You can demolish and remove the old surface, prepare the base, and pour a new slab; or you can use a resurfacing process to restore the slab to its youthful appearance.Sometimes a concrete slab is just too unstable or too badly damaged to make resurfacing possible. But when the problem is just superficial cracking, discoloring, or minor chipping or spalling, resurfacing is a very good option. It's a project that just about anyone can tackle, and it's a lot more affordable than replacing the concrete slab.What Is Concrete Resurfacer?There are lots of concrete mix products on the market—including mortars, repair patchers, fast-setting concrete mixes—and it can be hard to choose among them. Concrete resurfacer is a special cementitious product that blends ordinary Portland cement, fine sands, polymer modifiers, and other additives aimed at providing adhesion. Unlike other cement products, it is designed to be applied in very thin coats (no more than 1/2 inch thick), and its additives provide good adhesion to an existing slab.Concrete resurfacer should not be applied in cold weather. Make sure that the current temperature is at least 50 degrees Fahrenheit, and that the temperature will stay above 40 degrees for at least the next 24 hours. Also, work when the area is most shaded, or at least when the sun's glare is at a minimum. Finally, make sure there is no rain in the forecast for at least 8 hours after application.Concrete resurfacers are only available in one color—ordinary gray. But they can be tinted with colorants made specifically for concrete products. If you plan to resurface only part of a larger slab, be aware that it is hard to match colors. New concrete looks new, and old concrete looks old. If you really want to make the surface look new again, it's best to plan on resurfacing all of it.Most jobs require a second, and sometimes a third coat of resurfacer. The finish will be quite smooth, so you can add texture to the final coat by brushing it with a broom while it is still slightly wet.

By JARRETT MELENDEZWhen left exposed to the elements or accidental spills, concrete often becomes discolored if it wasn't properly sealed. If you've tried cleaning it with normal detergents and water to no avail, a few common household chemicals can get rid of the stains. To prevent further discoloration, consider sealing the concrete with a solvent- or silicone-based concrete sealer once you remove the existing stains. If these chemicals don't work, you may need to hire a professional cleaner.Step 1Wet down the concrete with a hose or bucket of water. This helps the baking soda stick to the surface.Step 2Pour baking soda over all of discolored areas. Lightly moisten the baking soda to form a paste. Scrub the baking soda into the concrete with a stiff-bristled scrub brush. Do not use a wire brush, as these can damage concrete.Step 3Allow the baking soda paste to sit on the concrete overnight. This allows the baking soda to absorb any compounds discoloring the concrete. Rinse the concrete thoroughly and allow it to dry.Step 4Apply vinegar or bleach to the discolored areas. If you use vinegar, do not dilute it. Pour it onto the concrete and scrub it into the surface with a scrub brush. If the discoloration starts to fade, repeat until it disappears completely. Add 3 tbsp. bleach to 1 gallon hot water, using the solution to scrub the concrete.

So you’d like a new stamped concrete patio, but already have a plain gray one. Does your contractor need to tear yours out before installing the new concrete? Maybe and maybe not. If done properly, new concrete can often be poured right over an existing slab. For this to be feasible, the contractor needs to pour at least 2 inches thick, use smaller aggregate, and incorporate reinforcement such as welded wire mesh or fiber mixed into the concrete. Steel rebar is also a good idea if the slab is thick enough to allow it. To clarify the point, this article deals with pouring concrete over concrete, not applying a thin polymer-modified stampable overlay, which is another option.Make no mistake…there are certain situations when it’s best to tear out existing concrete and start anew by pouring on a compacted stone or sand base. For instance, if you have large working cracks in your slab and the concrete has settled to the point that it’s at several different levels, you should remove it. Likewise, if tree roots are causing your existing concrete to heave, then it’s best to tear out the concrete, resolve the root problems, and start fresh. Perhaps door thresholds or stair riser heights are an issue and you simply can’t pour any higher without creating problems. Any of these are good reasons to remove the existing concrete and start from scratch.However, if your concrete is relatively sound and raising its elevation a few inches would not create problems, then you can pour new concrete directly over the old. Well, maybe not directly over the old. You’ll want to install a bond breaker so the two slabs do not bond to each other.“Why?” you may ask. “Don’t you want the new concrete to bond to the old?” The answer is usually no. If you bond new concrete to old, any cracks in the existing slab will transfer up into the new slab, and usually within a day or two. These include cracks located within sawed or tooled crack control joints. However, if you use a bond breaker such as plastic sheeting, roofer’s felt (tar paper), or a layer of sand or stone between the new and the old concrete, the existing cracks will not transfer through. The slabs will remain separate. You must, however, place crack control joints where needed to eliminate random cracking. In thinner concrete slabs, crack control joints should be spaced closer together than with full-depth (4 inch +) concrete.Some people contend that if they aren’t bonded together, the two slabs will somehow separate. Considering the enormous weight of the material, there is little to fear in that regard. The new concrete certainly isn’t going to float up in the air or slide off. Skeptics fail to recognize that pouring over the top of sound concrete is no different than pouring over a super-compacted stone base. Over the course of my 20+ year contracting career, I’ve poured countless 2 inch caps over existing concrete with no problems whatsoever. The photos included in this article are just a few of the many jobs I’ve completed using this method, and one of them is at my own home.Pouring atop existing concrete exposed to vehicular traffic is also being done on highway, driveway, and parking lot projects. It’s called whitetopping, and it is growing in popularity due to decreased expense and a proven track record. However, with slabs which will be exposed to vehicular traffic, the concrete is thicker and no bond breaker is used so the top slab is bonded to the existing slab. This seldom works with residential driveways leading into a garage because the added height makes the driveway taller than the garage floor.Don’t let the cost, mess, or headache of a complete tearout stop you from considering stamped concrete. Maybe you just need a cap-over!

Don’t hold off any longer on your garage floor project just because of some concrete pitting or spalling. Repairing a pitted or spalled garage floor is only intimidating because most people don’t know what to use or how to start. It really isn’t that difficult and in most cases can be tackled by the average DIY handyman. Once you understand what to do and which products to use, you will find that it’s much easier than you think.WHAT IS CONCRETE PITTING AND SPALLING?Pitting and spalling can sometimes look very similar to one another. Spalling will usually cause the surface of the floor to crumble or separate in thin layers. Pitting on the other hand can create smaller, deeper holes that have a more distinct jagged look.Spalling is generally caused from cold winter climates that subject the concrete to freeze thaw cycles. What happens is water is deposited on the garage floor and works its way into the capillaries of the concrete. When the water freezes, it expands and causes microscopic damage to the surrounding concrete.Over a few winters this constant damage weakens the surface and as a result, it starts to separate in sheets or crumble.Road salts and deicing fluids only contribute to making the problem even worse because it will allow the water more time to penetrate deeper into the concrete before it freezes.Pitting however can be caused from improper finishing of the concrete, an inadequate mix, improper use of an accelerator or even old age. Pitting can sometimes cover large areas of the floor while spalling may be more localized.PREPPING THE CONCRETE FOR REPAIRFortunately the majority of pitting and spalling in a garage can easily be repaired and isn’t as bad as it can be for concrete that is outdoors. Generally for a garage, the depth of the damage is usually less than ¼” for spalling and ½” for some pitting. Many times it is less than that.The first thing you want to do is clean the area to be repaired of any oil stains, wax, sealers, or anything that would be considered a bond breaker. Next, remove all broken and loose concrete with a hammer and chisel. It’s extremely important that you remove all loose or suspect material.Because spalling starts damaging concrete from just underneath the surface, there can be surrounding areas of your garage floor that haven’t weakened enough to break freely on its own and may be hidden. We highly recommend firmly tapping the surrounding areas with a hammer and listen for a hollow sound.Areas that sound hollow have deteriorated underneath and should be hit hard with the hammer to expose the damage for repair. This will eliminate the possibility of having to do any more repairs in the near future.After you are done, sweep the area clean and then vacuum the remainder of the dust from the surface.REPAIRING THE PITTING AND SPALLINGThere are a variety of products to use depending on the size of the repair you are making, how deep it is, and in some cases, how you want it to look. The type of product used is usually broken down into two categories; epoxy and polymer-modified cement.

An overview of polishing basics and the step-by-step processAs with any other specialized technique, polishing is a multi-step process requiring use of the proper tools and equipment to achieve top-quality results. To help you get started, here's a brief overview of the polishing process and a checklist of basic equipment and supply needs, along with some buying tips. Note that each job will present different conditions and challenges, so be sure to consult with your equipment and material suppliers for recommendations as to the products best suited for your application.POLISHING BASICSPolishing concrete is very similar to sanding wood. Machines equipped with diamond-segmented abrasives (akin to sandpaper) are used to grind down concrete surfaces to the desired degree of shine and smoothness. As when sanding wood, you gradually progress from coarser-grit to finer-grit abrasives. (In this case, grit is the particle size of the diamond.) The result is a glossy, mirror-like finish.You can polish concrete using wet or dry methods. Although each has its advantages, dry polishing is the method most commonly used in the industry today because it's faster, more convenient, and environmentally friendly. Wet polishing uses water to cool the diamond abrasives and eliminate grinding dust. Because the water reduces friction and acts as a lubricant, it increases the life of the polishing abrasives. The chief disadvantage of this method is the cleanup. Wet polishing creates a tremendous amount of slurry that crews must collect and dispose of in an environmentally sound manner. With dry polishing, no water is required. Instead, the floor polisher is hooked up to a dust-containment system that vacuums up virtually all of the mess.SUMMARY OF BASIC POLISHING STEPS· Remove existing coatings (for thick coatings, use a 16- or 20-grit diamond abrasive or more aggressive tool specifically for coating removal, such as a T-RexTM).· Seal cracks and joints with an epoxy or other semi-rigid filler.· Grind with a 30- or 40-grit metal-bonded diamond.· Grind with an 80-grit metal-bonded diamond.· Grind with a 150-grit metal-bonded diamond (or finer, if desired).· Apply a chemical hardener to densify the concrete.· Polish with a 100- or 200-grit resin-bond diamond, or a combination of the two.· Polish with a 400-grit resin-bond diamond.· Polish with an 800-grit resin-bond diamond.· Finish with a 1500- or 3000-grit resin-bond diamond (depending on the desired sheen level).· Optional: Apply a stain guard to help protect the polished surface and make it easier to maintain.

A polished concrete floor has a glossy, mirror-like finish. The design options for polished concrete are vast. You can choose nearly any color, create patterns with saw cuts, or embed aggregates or interesting objects into the concrete prior to polishing. The reflectivity of the floor can also be controlled by using different levels of concrete polishing. Polished concrete is popular in commercial buildings because it is easy to maintain. Maintaining polished floors requires dust mopping and occasional use of a cleaning product.Simply put, polishing concrete is similar to sanding wood. Heavy-duty polishing machines equipped with progressively finer grits of diamond-impregnated segments or disks (akin to sandpaper) are used to gradually grind down surfaces to the desired degree of shine and smoothness.Polishing ProcessThe process begins with the use of coarse diamond segments bonded in a metallic matrix. These segments are coarse enough to remove minor pits, blemishes, stains, or light coatings from the floor in preparation for final smoothing. Depending on the condition of the concrete, this initial rough grinding is generally a three- to four-step process.The next steps involve fine grinding of the concrete surface using diamond abrasives embedded in a plastic or resin matrix. Crews use ever-finer grits of polishing disks (a process called lapping) until the floor has the desired sheen. For an extremely high-gloss finish, a final grit of 1500 or finer may be used. Experienced polishing crews know when to switch to the next-finer grit by observing the floor surface and the amount of material being removed.During the polishing process an internal impregnating sealer is applied. The sealer sinks into the concrete and is invisible to the naked eye. It not only protects the concrete from the inside out, it also hardens and densifies the concrete. This eliminates the need for a topical coating, which reduces maintenance significantly (versus if you had a coating on it). Some contractors spread a commercial polishing compound onto the surface during the final polishing step, to give the floor a bit more sheen. These compounds also help clean any residue remaining on the surface from the polishing process and leave a dirt-resistant finish.You can polish concrete using wet or dry methods. Although each has its advantages, dry polishing is the method most commonly used in the industry today because it's faster, more convenient, and environmentally friendly. Wet polishing uses water to cool the diamond abrasives and eliminate grinding dust. Because the water reduces friction and acts as a lubricant, it increases the life of the polishing abrasives. The chief disadvantage of this method is the cleanup. Wet polishing creates a tremendous amount of slurry that crews must collect and dispose of in an environmentally sound manner. With dry polishing, no water is required. Instead, the floor polisher is hooked up to a dust-containment system that vacuums up virtually all of the mess.Many contractors use a combination of both the wet and dry polishing methods. Typically, dry polishing is used for the initial grinding steps, when more concrete is being removed. As the surface becomes smoother, and crews switch from the metal-bonded to the finer resin-bonded diamond abrasives, they generally change to wet polishing.Step-by-Step:· Remove existing coatings (for thick coatings, use a 16- or 20-grit diamond abrasive or more aggressive tool specifically for coating removal, such as a T-RexTM).· Seal cracks and joints with an epoxy or other semi-rigid filler.· Grind with a 30- or 40-grit metal-bonded diamond.· Grind with an 80-grit metal-bonded diamond.· Grind with a 150-grit metal-bonded diamond (or finer, if desired).· Apply a chemical hardener to densify the concrete.· Polish with a 100- or 200-grit resin-bond diamond, or a combination of the two.· Polish with a 400-grit resin-bond diamond.· Polish with an 800-grit resin-bond diamond.· Finish with a 1500- or 3000-grit resin-bond diamond (depending on the desired sheen level).· Optional: Apply a stain guard to help protect the polished surface and make it easier to maintain.

Question:My company was the contractor on a retail remodeling project that had an existing concrete floor requiring a grind and polish finish. We had to sawcut and remove portions of the floor for new underground mechanicals and then pour these sections back. Our job was to then grind and polish the entire floor to the level of gloss required. On the existing concrete areas, we had no problems. However we experienced problems from the start with the new concrete areas. The engineer involved with the project gave us a method of grinding that allowed us to achieve the correct sheen on gloss tests. Now less than six months later, these areas have failed miserably and the surface is visibly porous and is trapping dirt to the point where floor looks black in areas. The polishing contractor is claiming that this is a concrete finishing issue and the only way to take out the highs and lows of the concrete surface is to grind deep and expose the aggregate, but this would not be acceptable to the owner.Part of me agrees with the polishing contractor, but during a preconstruction meeting with the polishing company and project engineer, concrete finishing was a non-issue, and the finish did pass initial gloss testing. There have also been some comments about how the store has maintained the floor and their use of chemicals to clean it, which may have caused the concrete finish to fail. Any input you could give us would be great. We are a large general contractor in the Midwest, but our experience in grinding and polishing concrete is limited and we are hoping that this is not going to turn into an expensive lesson.Answer:Concrete, polished or not, should not pit and be weak on the surface. This usually indicates a mix design or curing issue. With situations like this involving many players, I like to go back to the start and focus on the key issue. In this case, the main issue seems to be that the replaced concrete sections are not holding gloss and polish because of surface deterioration that occurred soon after the floor was put into service - within the first six months.From the details you have provided, it appears that the replacement sections of concrete are failing and soft, either due to substandard mix design and concrete placement or post-applied chemicals. Polished concrete needs to be properly chemically hardened during the polishing process. This increases the surface hardness and provides better gloss. Lithium or sodium silicate hardeners are most commonly used. If applied properly, these should harden the concrete to a point where soft pitting does not occur, unless the concrete was so substandard that it was really soft and weak to start with.To zero in on what's causing the floor deterioration, the following questions need to be addressed:· Is there anything different about the replacement areas in regard to mix design and how the concrete was placed and finished? Did the concrete freeze after placement? What you need to look for is anything that might have created a weak surface.· What is the store using to clean the concrete? If a harsh cleaner is pitting the concrete, it would do it to some extent on all the concrete, not just the replacement sections.In regard to the finish, it is probably one of the most critical parts of preparing the concrete when polishing. The concrete mix design, placement, finish, flatness, and curing are all critical. If you get a soft slab, you end up with what you are experiencing. As for the repair, you can regrind to go deeper and get rid of the pitting, but this ignores the real problem in hopes of a quick fix. If the concrete is weak, the new grind will last another six months and then you're right back to where you started. I suggest taking a core sample or performing a surface hardness test. Also, do some research on the hardener that was used and make sure it was applied correctly and at the right coverage rate.

Stooping down to grind concrete floors along wall edges and in other tight spots by hand is a pain in the you-know-what, not to mention the strain it puts on your knees. With the compact walk-behind edger from Terrco, you can now do the entire task in a comfortable upright position and in much less time, making the machine especially advantageous on large projects with a lot of edging work.While the machine is only 16 inches wide and weighs 230 pounds, don't let the compact design fool you. The Terrco Edger is hefty enough to tackle heavy-duty concrete grinding work. "A number of customers asked us to design a machine that can stand up to the abuse most equipment sees on a jobsite," says Frank Vinella of Terrco. "Our edger was designed to be a heavy-duty edge machine, unlike machines on the market made of aluminum and plastic, which can break and bend."The machine was also designed for easy adjustability. It comes equipped with a free-moving guard with adjustable roller guides that allow the user to adjust how close the cup wheel comes to the wall. The wheels are also adjustable to control the height of the machine so the grinding wheel can be set square to the floor.The edger guard accommodates 7-inch (180 mm) diamond cup wheels or polishing pads. Cup wheels or pads from most manufacturers can be used, as long as they have 5/8-11 threading. Terrco also makes plates that allow the use of 3-inch diamond tooling. To change the grinding wheels, all you need is a wrench.Equipped with an onboard 7-gallon water tank, the edger can perform both wet and dry grinding. "For most jobs, the operator is able to go dry, but some floors need to be ground wet to help the tooling penetrate the concrete and stay cool," says Vinella. "It all depends on how the contractor is grinding the bulk of the floor. If they're grinding wet, then they want to do their edge work wet."Other features of the edger include:· A moveable arm to get into tight areas.· A grinding wheel speed of 1,760 rpm and abrasive pressure of 45 pounds.· Three horsepower, 230-volt, single-speed motor with magnetic start.· Rubber-tired roller-bearing wheels.

In all likelihood, the condition of the floor you’ll be polishing will have more impact on the final results than any other aspect of the project. It’s the key factor influencing the type of equipment and diamond tooling to use, the time and labor required to complete the job, the grit you should start with, the amount of densifier needed, and the production rates of your equipment and crews.Determining concrete hardnessThe degree of hardness, or density, of the concrete is the chief factor determining the type and grit of diamond to use. To determine concrete hardness, use a scratch test kit based on the Mohs scale of relative mineral hardness. This easy test makes it simple for you to determine where the concrete substrate ranks on the Mohs hardness scale and help you choose the most efficient and cost-effective diamond tooling for the job.Cleaning the floorIf the concrete floor has pre-existing oil stains, you’ll need to remove them first because they will inhibit the penetration of densifiers, dyes, and stains, resulting in unwanted color variations. Degreasers and detergents are usually sufficient for removing lightly soiled areas. For heavier oil stains, try using a poultice powder-a blend of dry absorbent clay that’s effective at extracting stubborn oil and dirt stains from concrete. For light oil stains, you can also try pouring mineral spirits onto the stain and then absorbing it with kitty litter.On some projects, you may need to remove vinyl tile or asphaltic adhesive membranes from the concrete surface prior to grinding. If vinyl tile needs to be removed from a large area, the most efficient method is to use a ride-on machine specifically designed to scrape the tile off the surface. These machines are useful for removing a wide range of materials from concrete surfaces including thick coatings (such as epoxies or urethanes), adhesives, thin-set mortars and floor coverings.If mastic or adhesive must be removed from the floor, the quickest method is to grind the material off, versus using a chemical stripping agent. Most manufacturers of grinding equipment and diamond tooling will have accessories designed specifically for this purpose.Repairing chips, spalls, and cracksWhen making repairs to the concrete before polishing, your goal is to blend the fix as closely to the surrounding concrete as possible. To get the best results, you must use specific products for specific repairs.For chips left behind from carpet tack strips, small divots and spalls, you can choose from a variety of different cement-based patching compounds, depending on the depth and severity of the affected area. Keep in mind, though, that even the best patch may not be an identical match to the rest of the polished floor. If you are repairing colored concrete, use a patching product that can be tinted to match the desired color.For minor flaws no deeper than 1/8 inch, try using a traditional skim-coat material used for overlaying concrete floors. For deeper flaws (1/4 inch or greater), use anchoring, or hydraulic, cement as a patching compound or even a self-leveling overlay if the flaws cover a large area.When dealing with cracks, you first need to determine if they are static or moving cracks. Static cracks (sometimes called “craze cracks”) are hairline flaws that only affect the surface of the concrete. Generally, this type of crack requires little if any attention and can actually add decorative interest once the floor is colored and polished. If you want to disguise the cracks, an effective method is to apply a tinted urethane as a skim coat.Moving cracks, also called “active cracks,” are more serious and typically must be repaired before you start polishing by crack chasing, cleaning, and filling. Crack chasing involves using a V-grooved diamond blade attached to an angle grinder or a walk-behind machine specifically designed to route out the crack. Next, thoroughly clean out the crack by removing all debris with a shop vac and then blow away any remaining dust with compressed air. To fill the routed crack, use a semi-rigid polyurea, which you can have color-matched to the floor, or apply a grind-and-fill repair material before polishing.Cleaning and filling jointsFilling contraction, isolation and construction joints is just as important as successfully polishing the floor-not only for aesthetic reasons, but also to greatly reduce the chance of the joint edges chipping and spalling, especially in commercial settings subject to heavy forklift and other vehicle traffic. Filling the joints will also make the floor easier to clean by preventing dirt from collecting in the gaps.The best method for the job is to fill the joints with a polyurea or semi-rigid epoxy at the beginning stages of the project. By cleaning the joints out first and then filling and ultimately grinding and polishing, any residual filler that flows out and isn’t scraped off will easily be removed during the coarse grinding step. Also, by filling the joint early, you’ll reduce the chance of chipping the joint edges during coarse grinding with aggressive metal-bond diamonds.The depth of the joint is also important. Check the filler manufacturer’s specifications for how deep the joint needs to be prior to filling. Generally, it’s best to apply the filler material full depth from the bottom to the top of the joint and leave a slight raised crown. Use a razor blade to scrape off the crowned filler flush with the floor surface after the material has set, and then proceed to grinding.

A step-by-step overview of the polishing processIt’s often desirable to polish the surface and edges of a concrete countertop to create a smoother, more aesthetically pleasing finish. In addition to giving your countertops an attractive sheen and exposing some of the aggregate or decorative add-ins, polishing will also remove small blemishes and flaws resulting from the casting process.Tools Required· A variable-speed (500 to 3,000 rpm) hand-held wet concrete polisher equipped with a built-in water feed and GFCI shutoff.· A set of diamond grinding pads, with grit levels ranging from coarse to fine. Both Buddy Rhodes and Jeff Girard use diamond pads with grit numbers ranging from 50 to 3,000. The more aggressive, coarser grits work best at exposing aggregates and removing blemishes. Youll use the finer grits for final polishing, progressing to higher grit levels until you achieve the desired surface sheen and smoothness.· A large squeegee.· Safety goggles and ear plugs.· Hand-held diamond blocks or pads for polishing areas of the countertop that can’t be reached by the electric polisher.And don't neglect the obvious: Be sure to buy diamond pads suitable for use with your grinder and specifically designed for grinding concrete, not granite. Concrete has rough, hard aggregate in a relatively soft matrix. Granite is uniformly hard. If you use pads designed for granite, they will not last as long or work as effectively, says Girard. Sources for concrete grinding and polishing tools and accessories include Applied Diamond Tools.Polishing StepsStep 1: Clean the fully cured concrete countertop by running water over the surface and then going over it with a squeegee to remove any grit that could gouge the concrete as you grind it.Step 2: If you notice minor flaws or tiny bugholes, be ready to fill these voids with a patching slurry prior to polishing. Slurries can be color-matched to the countertop or in a contrasting hue to create veining. You can mix up the slurry yourself using a combination of cement, fine sand, water, and pigment. But for greater convenience, consider buying a ready-to-use prepackaged slurry, which is often sold by the suppliers of countertop mixes. Be sure to get a product compatible with the mix you're using. Some are available in various pigments.Step 3: Start by polishing with the coarsest pad (typically 50 grit), depending on the desired finish. Go over the entire surface, including the edges, making sure to supply a constant stream of water to the surface as you grind. Keep the polisher level as you go.Step 4: After polishing the entire concrete countertop with a 50-grit pad, change to a 100-grit pad and polish the entire surface again. Repeat this process, working progressively through all the pads up to the finest 1500-grit pad. At this point, a sheen will begin to form. As you polish, periodically stop and squeegee the surface to remove any small bits of debris and check that you’ve exposed as much aggregate as desired. There are no hard-and-fast rules as to how long to polish with each pad. It depends on the hardness of the concrete and the results you want to achieve.Step 5: Use hand-held diamond blocks or pads to polish any areas of the countertop that can’t be reached by the electric polisher. The pads can also used smooth the edges of the countertop. Like the pads for the electric polisher, hand-held pads have variations in grit going from 120 up to 1500.Step 6: Allow the countertop to dry, and then apply a suitable food-safe concrete countertop sealer to prevent staining.

By JARRETT MELENDEZ  You certainly can sand concrete before applying a stain, but this may not be absolutely necessary. Sanding before staining ensures that the stain penetrates the surface, but this is only necessary if your concrete floor's surface is otherwise incapable of absorbing liquids. Consider your options before you rent sanding equipment and perform potentially unnecessary work.CleaningIf the reason you want to sand the floor is because of stains, try cleaning the floor first. Grease stains are particularly important to deal with before staining, because they can affect pigmentation and prevent proper color penetration. You can clean a cement floor by mixing 1 cup of trisodium phosphate or 2 tablespoons of degreasing dish detergent with 4 gallons of water and using a stiff-bristled scrub brush to scour the entire floor. You can remove remaining material and lose dirt by rinsing with water and vacuuming with a wet vac.Smooth ConcreteIf the concrete floors are particularly smooth or have been polished, you should sand them before staining. The best concrete surface for staining is rough and porous to allow good color penetration. Smooth, glossy surfaces will prevent all types of stains, even acid stains, from properly sticking to the floor.Water Absorption TestEven if the surface seems rough and porous, it may still need to be sanded. There's a very simple test you can perform to determine whether you should sand concrete before staining. Pour about one tablespoon of water onto the floor, then let it sit for 10 minutes or so. If the concrete floor completely absorbs the water, you can then stain it without sanding. However, if the water remains on the surface, you will need to sand the floor to ensure proper penetration.SandingConcrete requires heavier sanding equipment than wood. Unless you're working on a very small surface, you shouldn't try to do this by hand. The job will require a belt sander or a floor sander with heavy duty silicone carbide sandpaper. Grinders are also effective, but they can leave a rough texture that may not be desirable for your project. Ensure that you sweep up any dust you create and mop the floor well before staining to prevent compromising the job.

We typically recommend sealing and waxing floors on any kind, but it is especially important for interior staining or any exterior areas that are high traffic. Sealing and waxing floors greatly enhances the colors, look and luster. While protecting the floor from damage and making cleaning and maintenance of the floors substantially easier and less expensive. Sealing concrete removes the porous quality of the concrete and coats it, protecting it from spill stains and damage caused by erosion, weathering, heavy traffic and use.. The advantage to adding wax on top of the sealant is that it acts as the sacrificial coat and makes the process of upkeep much simpler: when the wax gets worn down or scratched, simply apply a new coat of wax and you are back in business. So while you don't have to seal concrete, if you do, you will be enhancing and protecting the look of the concrete while extending it's lifespan considerably. Will Sealing Concrete Change Its Appearance? In short, yes, sealing concrete will change the appearance of your concrete. Leaving concrete unsealed will leave it with a flat look. The color will remain flatter and dull, in addition to the concrete remaining porous and easier to damage. Sealing the concrete will enhance the colors and give it more of a marble or mottled look, smoother and with richer colors. If you are after a less shiny or more muted tone, you can apply a matte wax on top of the sealer to get a flatter look.Another thing to point out is the cosmetic difference between water base and solvent base sealers. Solvent base sealers tend to over darken concrete stain, looking as it does when saturated wet with water. Water base sealers such as Clear Shield, makes the concrete look as it does when damp with water, not saturated wet but not dry either. Rather, in between, damp. Which brings out the marbling, mottling and subtle color variances more, while maintaining a more natural look.Will Sealing Concrete Make It Slippery?A common question that we also get is "Will sealing stained concrete make it more slippery"? We consider this to be kind of a trick question. Anytime you are applying any kind of concrete sealer, it will usually be more slippery than unsealed concrete, especially when wet. But there are a few factors at play here. Solvent based sealers are definitely more slippery than unsealed concrete, but water based sealer is less slippery (if applied properly) than a solvent based sealer. This is one of the reasons that we suggest water based sealer over solvent based. Our water based sealer is meant to be applied in two thin layers on well brushed concrete. If applied properly, it should not make the sealed concrete much more slippery than the unsealed version. We also sell a traction additive that you can apply to the sealer to help with this issue if it arises. Also, when applying the wax over the sealer, it helps a lot because the wax is less slippery than the sealer. If you're concerned with how slippery it will be, then as always, we suggest that you  apply the sealer to a small test area, to test out both the appearance of the sealed concrete and see how slippery it is, before doing the entire area.ConclusionSo, there really isn't a benefit to not sealing your concrete unless for some reason you want it to have a duller color. We would still advise sealing the concrete, but applying a matte wax instead of a glossy one to get the appearance that you desire. The benefits (especially for floors and exterior concrete) in terms of protection and maintenance really can't be overstated. Sealing anything exposed to the weather is incredibly important and if you are looking for a beautiful piece of concrete art that lasts, sealing and waxing is the way to go.

By JULIE KEYESCement mixes are formulated and packaged at plants across the United States. However, not every company uses the same formula, or even the same ingredients. Even contractors in the same area may use different brands. Because of this, new or replacement cement will almost certainly not initially match the tone of the older cement. There are some ways to artificially age and darken new cement, but matching 100 percent is difficult.Step 1Purchase several test bags of cement and mix small batches in small buckets. Label the individual cement samples and allow them to dry completely. Place the samples on the existing cement and pick one that looks the most similar. Pour a coating of the new cement over the top lighter surface, trowel it smooth, and let it harden.Step 2Place a layer of fresh topsoil over the new cement and wet it with a garden hose. Let the soil stay there for a few days, and wet it repeatedly as it starts to dry out. Remove most of the soil with a shovel, leaving only a small amount. Walk on it repeatedly to darken the cement. Though it may not match perfectly, it should darken somewhat.Step 3Pour a small amount of concrete stain in a small bucket and add water to thin it. Test the stain and let it dry on sample concrete to see if it matches the color of the existing cement when dry. Add more water or stain as necessary to get it close to the same and then brush the stain on the new cement.

by Jason SpanglerExcess moisture doesn’t just evaporate; it takes your design with it. You can preserve your design and the concrete with proper moisture testing before stains and sealers are applied.Beauty and strength converge in decorative concrete. Like a good acid stain, they fuse together to create a durable, pleasing floor that literally becomes the foundation of its space and atmosphere. Achieving the desired result requires that you consider a number of variables for the specific stain and sealer combination you select.One of the most important variables that need your attention is the moisture content in the concrete at the time the stain and sealer are applied. Moisture in concrete can come from two main sources. The first is the volume of water used to mix the cement into concrete. Second, external sources of water may be an issue, such as water that can migrate from the ground to the concrete slab in the absence of a vapor retarder.Both evaporating water and pooled water can interfere with a stain or sealer.Signs That the Finish Was Applied at the Wrong TimeThe damage that excess moisture can do to your stain or sealer can look different depending on the amount of excess moisture and the type of stain or sealer used. Here are some common indicators that the stain or sealer was applied too soon – before the concrete had a chance to dry sufficiently:Why is my concrete turning white?Efflorescence is a white salty residue caused when too much moisture is moving through the concrete. As the concrete dries and its moisture rises upwards through the slab, it brings salts within the concrete to the surface as well. As lovely as the word sounds, efflorescence is rather unsightly.Depending on whether or not the floor has been finished yet, efflorescence manifests in different ways. It can leave a white powdery substance on the concrete’s surface after staining but before sealing. If the efflorescence gets trapped underneath a sealer and/or certain stains, it will look like a white “blush” has been spread on the concrete.

Salt and deicers create a chemical mix that, diluted with enough water, seeps into concrete. The brine re-freezes when temperatures drop, then evaporates when temperatures warm - leaving damaged concrete and salt stains.Don't let your clients wait for a nasty springtime surprise!Educate them on the effects of winter, and begin booking appointments now to evaluate, clean, repair and coat their concrete garage floors to prevent any further damage. Or, encourage clients to book their spring clean-and-coatings now, perhaps at an early-bird discount.How do you remove salt stains from concrete?CAUTION: Contrary to what your first instinct may be, do NOT use a pressure washer. With high water pressure, you run the risk of driving the salty solution deeper into concrete - only to reappear again when the water evaporates. 1. Clear any debris and clean the entire garage floor of other contaminants, thereby exposing damage or salt stains. 2. To remove salt stains, prepare a solution of 1 cup vinegar and a squirt of dish soap to every gallon of warm water. (Water alone won't work and may just move the salt around and re-deposit it). 3. Apply the vinegar mix to stains and scrub with a stiff brush or broom. 4. Thoroughly remove the residue with a mop or wet vac, to prevent the road salt from being redeposited into the concrete pores. 5. Rinse thoroughly with water. 6. For tough salt stains, repeat the process. Or, try a commercial-grade cleaner. Apply and remove residue in the same way as described above, to prevent re-dispersing the salt back into concrete pores. 7. For the most stubborn salt stains, you can use a mild acid-etch solution. 8. Once the salt is removed, it is time to repair any damage that may have been caused by winter's harsh effects.