CC Intro

Concrete ClothTM

GCCM

(GCCM - Geosynthetic Cementitious Composite Mat)

Steve L. Neschleba – Region Manager, Eastern US

Tool for your Toolbox

Concrete Cloth can be an option when addressing:

1. Secondary containment dike protection

2. BMPs (temporary and/or permanent)

3. Water Quality

4. Stormwater Management

5. Erosion Control

6. Hard armoring protection

7. Weather Constraints

8. Access restriction

9. Lack of material sources

10. Weed Control

11. Building Envelope

What is it?A flexible cement-impregnated fabric that hardens when hydrated to

form a thin, durable concrete layer.

Concrete Cloth consists of:

- Dry concrete mix

- Reinforcing fiber matrix

- Fabric top surface

- PVC bottom coating

What is Concrete Cloth GCCM?

Fabric top surface

Water impermeable PVC coating

Concrete mix and reinforcing fibers

CC Section View

3-DIMENSIONAL MATRIX (FABRIC REINFORCED)

Permeable Fabric

Top Surface PVC Bottom Surface3-Dimensional Substrate

Concrete Cloth is a Simple-to-Use

Geocomposite Protection Material

• Install like a geotextile

• Hydrate using water

• In 24 hours, it cures into a hard fiber-

reinforced concrete layer

Concrete Cloth can be used:

• Anywhere a hardened protective surface is required.

• Especially where conventional concrete is difficult or impossible to install.

• Where labor is expensive or scarce.

Milliken Concrete Cloth GCCM

Ditch and Channel Lining

Milliken Concrete Cloth GCCM Applications


Slope Stabilization


Culvert Lining

Concrete Cloth GCCM comes in two roll varieties:

Bulk RollsPortable Batched Rolls

Product Dimensions/Roll Sizes

Large engineering firms, contractors & asset owners

Who’s using Concrete Cloth GCCM?

CHANNEL LINING

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Concrete Cloth for channel lining – value statement

• Provides a hard armor surface protection while minimizing infiltration into

the subgrade (very low permeability)

• CC is fiber reinforced and has an abrasion resistance twice that of ordinary

Portland cement

• Concrete Cloth can be installed by maintenance crews minimizing

specialized equipment

• Minimize traffic closures /delays

• Flexibility to work with pending weather

I-85 Business & US 176 InterchangeSpartanburg, SC

Flume & Drainage Ditch

Completed May 2013

Concrete Cloth Case Study: Spartanburg, SC

Project Details:

Customer: South Carolina Department of

Transpiration

Issue: Existing flumes were damaged and

Concrete Cloth allowed SCDOT to avoid the

use of forms and required no lane closures or

special traffic control.

Installation dimensions:

• Total 3000 ft2

• CC5

Installation Time: 4 hrs

Original flumes were damaged and required frequent maintenance. The flumes

were re-graded and sumps were created to slow water velocity.


Anchor trenches were dug and Concrete Cloth was rolled out. The finished

installations were then hydrated and the trenches covered.


An outlet ditch for an existing culvert was also installed the same day.


The same flume and culvert outlet 2 years after installation.


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SLOPE PROTECTION

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Concrete Cloth for slope protection– value statement

• Provides a hard armor surface protection while minimizing infiltration into

the slope face (can provide surficial stability utilizing percussion anchors)

• Installation for applications with limited headroom or equipment access

• Installation rated of 5,000-8,000 sf per day for large projects

• Steep slope applications – 2:1 or steeper (using percussion anchors)

• Install cut-off anchor trenches to prevent undermining of armored slope

I-95/Highway 87 NCDOT BridgeFayetteville, NC

Slope Foundation Protection Erosion Control

Completed May 2013

Concrete Cloth Case Study: Fayetteville, NC

Project Details:

Customer: North Carolina Department of

Transportation

Issue:

• Leaking bridge joint causing erosion of the

foundation slope below. This area was under

constant repair.

Installation dimensions: Slope protection

• 20 feet x 30 feet

• Total 600 ft2 Installed (CC8)

Alternate Option:

• Replacing the bridge joint would require major

disruption by closing lanes of traffic on I-95

• Vegetative slope was impractical and required

continuous maintenance

Leak from the bridge joint above is causing erosion of the slope foundation

below. The slope was smoothed. Concrete Cloth is rolled out over the slope. Pins

are used to hold the material.


Backfill was placed around the edges of the Concrete Cloth. A water truck was

used to hydrate the material. The hydration and installation was completed in 2

hours with no lane closures to the Interstate above.


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Percussion Anchors

The general pullout strength of percussion anchors in the fields:

A) TLA -2 ( 400 lbs peak) and average around 250-300 lbs

B) TLA-3 ( 600 lbs peak) and average around 300 -400 lbs

Ohio DOT Slope Protection

https://youtu.be/HhilK7g-onU

https://youtu.be/HhilK7g-onU

INSTALLATION

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How is Concrete Cloth Installed?

For larger Bulk Rolls, spreader bars are often used to install Concrete Cloth

Subgrade Preparation

Hydration


Concrete Cloth is rolled from the bottom of bulk roll to ensure the correct side is

facing up. Fabric side faces up, pvc side faces down

It can be shingled in the direction of flow, or installed with longitudinal seams

Installation Tools

Concrete Cloth can be cut and sized with simple hand tools (for larger installations

you can use a small grinder to cut material faster)

Overlap Joint

4” overlap with adhesive (as shown below)

Adhesive can be purchased at Big Box (Lowes/Home Depot)

Mechanical Seaming

Concrete Cloth is secured to itself (with screws and washers) to prevent

detachment and can be sealed to make water tight joints. No. 14 stainless

steel screws (hex head, course threaded) with1”-2” stainless steel fender washer

CC Type Screw Length (min.)

CC5 3/4”

CC8 1”

CC13 1 1/2”

Anchoring & Trenching

Concrete Cloth is typically installed in an anchor trench to prevent undermining;

Different anchoring systems (i.e. Platipus, etc) can be utilized with Concrete

Cloth depending on application and design requirements

INVERT LINING

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Concrete Cloth for culvert invert lining– value statement

• Provides protection of invert by fastening Concrete Cloth to area needing

protection

• Pipe should be in good structural integrity –Concrete Cloth provides new

invert wearing surface where abrasion is occurring (will not protect from

soil side corrosion); when installed can also help prevent backfill loss due

to invert loss and pitting

• Pipe can still be relined in the future

• Concrete Cloth’s cement composition (not Portland) adds to its durability

Concrete Cloth Case Study: Richmond, VA

Project Details:

Customer: Virginia DOT

Issue: (3) barrels of a triple barrel culvert

needed preventative measures to extend

service life.

Installation dimensions:

• 90 feet long (CC13)

Alternate Options:

• Dig and replace was not an option

• The city did not have the money for a full

rehabilitation at the time of the project.

Corrosion of the culvert was seen at the flow line and the shape of the culvert

appeared to be in its original geometry. Due to the access limitations, the VDOT

maintenance crew chose to install the Concrete Cloth perpendicular to the

direction of flow.


A Ramset was used to attached the Concrete Cloth to the culvert. The Concrete

Cloth was hydrated with water sourced from a truck brought to the site.


Duration of installation was~ 5 hours – this was the first installation by VDOT.

The edges of the CC were sealed with a non-shrink grout.


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Abrasion Resistance: Taber Abrasion

• Equipment: Taber 5150 Abraser

• Two H22 Abrasive wheels (coarse/high

abrasion)

• 1000 g weights on each wheel

• Estimate ~18 psi pressure at abrasion

surface

• Resurface abrasive wheel with diamond tip

every 500 cycles

• Measure change in mass and change in

thickness versus number of cycles

• Testing similar to ASTM C-1353


500 Cycles 1500 Cycles 2000 Cycles 6500 Cycles

Concrete Cloth has abrasion resistance similar to high

compressive strength concrete, but will not fall apart

(fiber reinforced) as it experiences wear.

2400 psi Concrete, 4700 cycles 9300 psi Concrete, 5000 cycles Concrete Cloth CC8, 6500 cycles



• Concrete Cloth Design Life is based on estimates of wear from

abrasion resistance – which is assumed to be the method of failure in

many applications.

• Based on the previous measurements, once the fabric on the surface

abrades, Concrete Cloth will be approximately 7.5X more resistant

under the same conditions than a typical 2500 psi concrete.

• The design life of 25 years is based on the currently observed rates of

abrasion for standard concrete materials, and the correct Concrete

Cloth thickness should be chosen based on the expectant abrasion

environment, much the same as the thickness of standard concrete

would be designed.

Equivelent Thickness of 2500 psi cement (in)

CC5 1.48

CC8 2.36

CC13 3.84

2400

Culvert Lining Detail – Installation Detail Transverse

Culvert Lining Detail – Installation Detail Longitudinal

Culvert Lining Photos (10’ Diameter CMP)

Culvert Lining Installation (CMP - manufactured pipe)

Hammer Drill Self Tapping Stainless Steel

Screw 1.25” long for CC8 lining

Culvert Lining Photos (Steel Multi-Plate)

Culvert Lining Installation (Steel Multi-Plate)

Powder Actuated Gun Powder Actutated Fastener w/Washer

Culvert Lining Installation (Edge Sealant)

BituminousElastomeric Sealant

Misc. Pipe Repair

CC Intro

Engineering

Transcript of CC Intro